A 27.Feb.2015 ISSUED FOR APPROVAL G. S. JUNG W. S. LEE H.

C CHOI
REV. DATE DESCRIPTION DESIGNED CHECKED APPROVED
OWNER

PROJECT

SHUQAIQ STEAM POWER PLANT

ENGINEER

CONTRACTOR

SUBCONTRACTOR : VENDOR INTERNAL DOC.NO

Sung Chang A. Al- Shaikh Contracting Co., Ltd. N/A

THIS DOCUMENT IS NOT TO BE USED FOR
CONSTRUCTION OR FOR ORDERING MATERIAL UNTIL APPROVAL/CERTIFICATION INFORMATION
CERTIFIED AND DATED.THE CONTRACTOR HHI DOC. NO :
CONFIRMS FULLY COMPLIANCE WITH THE O/E’S REV. NO :
COMMENTS. NO OTHER CHANGES HAD BEEN MADE ON DATE :
THE DOCUMENT. THE CONTRACTOR MAY SUBMIT THE STATUS :
DOCUMENTS AS “FOR CONSTRUCTION”

DOCUMENT TITLE

Method Statement for Structural Steel Work

CONTRACT NO. DOCUMENT NO NO. OF PAGES REV.

31221097/00 S-00-ULF-M-46-001-002 40 A
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CONTENTS

1. Introduction-----------------------------------------------------------------------------------------3

2. Applicable Code and References-------------------------------------------------------------3

3. Definitions------------------------------------------------------------------------------------------5

4. Performance Requirements--------------------------------------------------------------------5

OE COMMENTS:
5. Material Handling----------------------------------------------------------------------------------7
1.HHI had submitted three documents under same “Document Title- Structural Steel”, but following
different “Document Number”.
6. Erection----------------------------------------------------------------------------------------------9
i. S-00-ULF-M-46-001-001 Method Statement - Structural Steel Work for Pressure Parts
ii. S-00-ULF-M-46-001-002 Method Statement - Structural Steel Work for Non-Pressure parts
7. S-00-YAS-B-46-002-001
iii. Bolted Connection-------------------------------------------------------------------------------15
Method Statement - Structural Steel Work for STG Buildings
To avoid any confusion, HH must specify the Location/ Structure in “Document Title” and Clause 1.
8. Welded Connection------------------------------------------------------------------------------19
Introduction.
2.Clause 1.3- Introduction:
AnyInspection
9. conflicts and deviations
and must be brought to the attention of OE.
Tests-----------------------------------------------------------------------------22
3. Clause 2.- Applicable Code and References:
Related SSPP Project Technical Specification/s are to be referenced in this document.
10. Repairs---------------------------------------------------------------------------------------------24
4.Clause 4- Performance Requirement:
Quality Audits and Inspections must only be carried out as per approved procedure.
11. Floor Plate and Grating------------------------------------------------------------------------25
5.Clause 7.1- General Bolted Connections:
All bolts in elevated steelwork connections shall be minimum grade ASTM A325 as per clause 9.6.14.1 in
12. Coating
Project Repair-----------------------------------------------------------------------------------25
Technical Specification.
6.Clause 7.2- Bolt Torque Bolted Connections:
Torque
13. ToolCalibration certificates are to be submitted.
and Equipment-----------------------------------------------------------------------------25
7. Clause 8- Welded Connections:
Alterations of steel elements or welding, if any, at site must be approved by OE before execution.
14. Safety-----------------------------------------------------------------------------------------------26
8.Clause 12-Coating Repairs:
Coating repair, if any, must be approved by OE.
15. Risk Assessment---------------------------------------------------------------------------------37
9. Clause 15- Risk Assessment:
Safety risk assessment must be reviewed with OE HSE officer on site and adjusted as directed and related
permit to work must also be agreed by OE HSE officer.
10. See other comments on pages: 10, 12,15,17,18 & 21.

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1. Introduction

1.1 Purpose
The purpose of this Method Statement is to provide the structural steel erector with details of steel erection
requirements for SSPP-1 Project.

1.2 Scope
This Method Statement defines the requirements for the receipt, handling, erection, assembly, and field
inspection of structural and miscellaneous steel. Offshore structures and pre-engineered metal buildings are
excluded from the scope of this document.

1.3 Conflicts and Deviations

Any conflicts or inconsistencies between this Method Statement, shop drawings, erection drawings or other
Contract Documents shall be brought to the attention of Purchaser for resolution.

2. Applicable Code and References

When adopted in this Method Statement or in the Contract Documents, the latest edition of the following
codes, standards, specifications, and references in effect on the date of contract award shall be used, except
as otherwise noted. Short titles will be used herein when appropriate.

2.1 Codes and Standards

Comply with all applicable codes and standards including but not limited to, those listed below:

● American Institute of Steel Construction (AISC)

- AISC Allowable Stress Design(ASD) Specification for Structural Joints Using ASTM A325 or
A490 Bolts
- AISC Code of Standard Practice for Steel Buildings and Bridges
- AISC Manual of Steel construction, Allowable Stress Design(ASD)
● American National Standards Institute (ANSI)
- ANSI A10.13 – Steel Erection – Safety Requirements
● American Welding Society (AWS)
- AWS D1.1/M – Structural Welding Code – Steel

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● American Society for Testing and Materials (ASTM)

- A123 - “Zinc (hot galvanized) coatings on products fabricated from rolled pressed and forged
steel shapes, plates, bars, and strip.”
- A153 - “Zinc coating (hot dip) on iron and steel hardware.”
- A780 - “Repair of damaged hot dip galvanized coatings.”

● Process Industry Practices(PIP)

- STS05130 – “Erection of Structural and Miscellaneous Steel Specification”

● U.S Department of Labour, Occupational Safety and Health Administration(OSHA)

- OSHA 29 CFR Part 1910
- OSHA 29 CFR Part 1926

2.2 Related Contract Procedures

● HHI QA/QC Specification List

- EHS Management Plan (S-00-TAA-T-44-015-001)
- Painting Specification (S-00-TBB-T-32-001-001)
- Quality Audit Procedure (S-00-TAA-Q-43-003-001)
- Non Conformance Control Procedure (S-00-TAA-Q-43-004-001)
- Welder and Welding Operator Qualification Procedure (S-00-TTA-Q-43-005-001)
- Material Receiving Inspection Procedure (S-00-TAA-Q-43-008-001)
- NDE Procedure for Structure (S-00-TAA-Q-43-014-001)
- Inspection Procedure for Structure (with ITP) (S-00-TAA-Q-43-019-001)
● Others
- Method Statement for grouting work of static equipment (S-00-ULF-M-46-003-001)
- Method Statement for steel structure site repair works (S-00-ULF-M-46-002-001)
* Erector shall usually confirm to latest version for above Procedures.

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3. Definitions

Purchaser : The party who awards the contract to Erector. For this project, Hyundai Heavy Industries
Co., Ltd

Purchaser’s Inspector : The authorized representative of Purchaser with authority to act in the interest
of, and on behalf of, Purchaser in all quality assurance matters

Contract Documents: Any and all documents that Purchaser has transmitted or otherwise
communicated, either by incorporation or reference, and made art of the legal contract agreement or
purchase order between Purchaser and Erector

Engineer of Record : Purchaser’s authorized representative with overall authority and responsibility for
the structural design

Erector : The party responsible for the erection of the structural and miscellaneous steel. Unless
otherwise noted, the term Erector shall apply also to the Erector’s subcontractor(s) and/or vendors

Erector’s Inspector : The authorized representative of the Erector with responsibility for the quality
control of all materials, installations, and workmanship furnished by the Erector and any of the Erector’s
subcontractors or vendors

4. Performance Requirements
4.1 Quality Control

1) Purchaser shall be solely responsible for the quality control of materials, installations, and
workmanship at the job site.

2) Erector shall have a written Quality Control Program and Inspection Procedures document that shall
provide details of how compliance with the requirements of this Method Statement and the shop and
erection drawings shall be achieved. Erector shall maintain a complete up-to-date set of erection
drawings at the job site.

3) All welding procedures and individual welders shall be qualified in accordance with the requirements
of AWS D1.1/M

4) All welding inspectors shall be qualified and certified as AWS Certified Welding Inspectors in
accordance with the provisions of AWS D1.1/M.

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5) Erector’s Inspector shall inspect all materials, installations, and workmanship of Erector to ensure
conformance with all requirements of this Method Statement and the Contract Documents prior to
offering for inspection to the Purchaser.

6) Purchaser’s Inspector and Owner’s Representative shall have the right to inspect all materials,
installations, and workmanship installed by Erector and shall have unrestricted right of access to
Erector’s work areas.

7) Purchaser’s Inspector may reject any improper, inferior, defective or unsuitable materials,
installations and workmanship of Erector. Any rejected materials, installations, and workmanship
shall be repaired or replaced by Erector per Purchaser’s instructions at no cost to Purchaser subject to
the approval of the Owner.

8) Erector shall provide all inspection tools and shall provide inspection access facilities such as
platforms, ladders, and scaffolds as requested by Purchaser’s Inspector.

9) Inspection tools and tool calibration records for tools used by Erector shall be maintained and
available for examination by Purchaser’s Inspector.

4.2 Safety

1) The Safety Program shall address the safety measures that Erector shall use during steel erection work,
The Safety Program shall comply with the requirements of the Contract Documents, AISC ASD
Manual of Steel Construction, AISC Code of Standard Practice for Steel Construction, applicable
portions of OSHA 29 CFR Part 1910 and Part 1926, and other applicable federal, state, or local
requirements.

2) Erector’s Safety Program shall provide a detailed description of how Erector will prevent injury to all
personnel affected by Erector’s operations. The Safety Program shall include an effective system for
initial orientation and education in safety and accident prevention, as well as appropriate records to
document compliance. As a minimum, the Safety Program shall place particular emphasis on the
following aspects :

a. Fall prevention
b. Ground level pre-assembly to minimize elevated erection
c. Hole covers and opening barriers
d. Access control to incomplete areas of erection
e. Lifting plans and hoisting procedures

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4.3 Assembly Lift Plan

Erector is responsible for assuring that all pre-assemblies not specifically shown or noted on the design
drawings to be pre-assembled prior to lifting will maintain structural integrity during lifting.
1) A written Assembly Lift Plan shall be prepared for assemblies larger than 50 feet(15 meters) in one
direction, larger than 2000 square feet(186 square meters) in plan areas, any lift over 50 tons is an
“Engineered Lift”, which requires drawing of the lift that will be contracted and a Rigging or Lift
Engineer to be present at the scene when the lift is being performed. The Assembly Lift Plan shall
demonstrate that the proposed lift shall be performed safely and that the assemblies being lifted will
remain free from distortion or undue bending, and will maintain structural integrity during the lifts.
2) The Assembly Lift Plan shall contain detailed data on the extent of the lifted assembly, its weights,
the structural calculations that prove structural stability of the assembled components during lifting
operations, verification of the capacity capabilities for any cranes utilized in the lift, location and
positioning of the cranes, and a description of the rigging to be utilized.
3) Review of the Assembly Lift Plan by Purchaser does not relieve Erector of responsibility required for
the safe erection and/or lifting of any component, structural assembly, or any other item under the
control of Erector.

5. Material Handling

5.1 Receiving

1) All materials designated for the care, custody, and control of Erector shall be received, unloaded,
stored, and otherwise handled in a manner that will prevent distortion, deterioration, damage, or
staining, Materials shall be kept free of dirt, grease, and other foreign matter.
2) Erector shall receive, unload, sort and store all materials to be erected at the jobsite in a designated
area on aboveground platforms, skids or other supports in such a manner that any deformation or
damage of shape, plate etc. shall be avoided.
3) All bolts, nuts, washers, plates etc shall be transported to Site in properly marked and sealed
containers, suitably protected to prevent damage during transportation.

5.2 Inspection

1) Unless otherwise required by Purchaser, all materials shall be inspected by Erector immediately after
receipt to ensure that the materials are not damaged, that all items on the packing list have been
supplied, and that all documentation has been received.
2) If any damage is discovered, or any parts, components, or documentation are missing or otherwise
defective, the occurrence shall be immediately reported to Purchaser in writing.

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3) Erector shall inspect all materials to be erected for damage at the time of unloading and just before
commencing the erection and submit written reports to the Purchaser. Any damage occurred during or
after unloading shall be the Erector’s responsibility to repair as directed by the Purchaser.
4) The Erector shall unload and store all fabricated steel at the site. Any structural steel or accessories
arriving at site in a bent or distorted condition shall, when permitted, be properly straightened by
Erector.

5.3 Storage

1) Store all members in a manner for easy access identification and inspection. Locate steel member off
the ground using pallets, platforms or other supports. Protect steel members and packaged materials
from corrosion and deterioration.
2) Store materials to permit easy access for inspection and identification. Keep steel members off ground
and spaced by using pallets, or other supports and spacers.
3) Protect steel members and packaged materials from erosion and deterioration.
4) Store fasteners in a protected place. Clean and re-lubricate bolts and nuts before use.
Fasteners bolts and small fittings shall be stored under cover in dry conditions.
5) Do not store materials on structure in a manner that might cause distortion, damage, or overload to
members or supporting structures. Repair or replace damaged materials or structures as directed. If
galvanized surfaces are damaged, they are to be repaired in accordance with clause 8 of Painting
Specification (S-00-TBB-T-32-001-001).
6) Erector shall protect galvanized surfaces prior to erection against damage.

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6. Erection

6.1 General

1) Erection shall be in accordance with the drawings and other Contract Documents, the AISC ASD
Manual of Steel Construction, the AISC LRFD Manual of Steel Construction, the AISC Code of
Standard Practice for Steel Buildings and Bridges, OSHA 29 CFR Part 1910 and Part 1926, and any
applicable state, municipal, or local regulations or codes.
2) Any circumstances discovered by Erector which affect progression, performance, or completion of
Erector’s work activities such as discrepancies between the erection/shop drawings and the delivered
steel members, incorrectly fabricated steel members, or incomplete or unacceptable work of other
contractors affecting Erector’s work shall be immediately reported to Purchaser in writing.
3) Any damage caused during erection shall be reported to Purchaser. Corrective measures shall be
completed as directed by Purchaser at no cost to Purchaser.
4) Erection of steel joists shall conform to the requirements of the Steel Joist Institute(SJI) and the joist
manufacturer and AISC Standard Specifications for steel joists.
5) Temporary erection loads or permanent loads shall not be placed on any incomplete portions of the
structure being erected unless Erector can demonstrate by analysis that the contemplated action is safe.
6) Loose timbers, metal sheeting, bolt buckles, tools, debris, and temporary scaffolding shall be kept
restrained or removed from work areas. Erector shall be responsible for securing all equipment and
materials within Erector’s care, custody, and control during the erection operation.
7) Erector shall maintain the job site in clean and safe condition at all times and shall properly dispose of,
off premises, all crating, waste materials, and other refuse which has accumulated as a result of
Erector’s activities under this Instruction.
8) Lifting of painted structural members shall be done with a non-abrasive choker.
9) Erector shall keep a daily record, by piece number, of all material erected.
10) Before commencing work, Erector shall check foundations and other connection points to confirm
their location, orientation, elevation, and condition with relevant civil records.
After finishing inspection with civil inspector, Erector shall hand over foundations.
11) Establish permanent benchmarks necessary for the accurate erection of structural steel. Check
elevations of concrete and masonry bearing surfaces, and locations of anchor bolts and similar items,
before erection proceeds.
12) Provide temporary planking and working platforms in accordance with the referenced Construction
Safety Manual.
13) Erection of steel deck shall conform to the requirements of the Steel Deck Institute(SDI) and the deck
manufacturer.

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14) Erector shall participate and cooperate with Civil Constructor for the setting of anchor bolts during
the construction of foundation, when Erector is decided before this work.
15) In order to increase accessibility, platform flooring, stairways, and ladders shall be installed as
practical as possible.
16) Items such as davits, trolley beams, etc., which might be used to facilitate construction, shall be
installed as practical as possible.
17) Set structural frames accurately to the lines and elevations indicated. Align and adjust the various
members forming a part of a complete frame or structure before fastening permanently.
18) Clean the bearing surfaces and other surfaces which will be in permanent contact before assembly.
19) Perform necessary adjustments to compensate for discrepancies in elevations and alignment within
specified limits.
20) Level and plumb to be done tier by tier and final overall with AISC tolerances specified.
21) Comply with AISC specifications for bearing, adequacy of temporary connections, alignment, and the
removal of paint on surfaces adjacent to field welds.
22) Components shall be handled and stored in such a manner as to minimize the risk of surface abrasion
and damage.

6.2 Erection Method

1) The Erector shall prepare a written method statement, taking into account the requirement of the
design, erection procedure and program, respectively.
2) The Erector shall submit the method statement to the Purchaser for acceptation at least 4 weeks prior
to the start of erection since the owner has to approve this procedure.
3) All nominated subcontractors shall follow this approved Method Statement.

6.3 Erection Tolerance

The tolerance for the erection of structural members shall be in accordance with the specifications or codes
specified in the job specification.
Specify which section of the code as reference(section no., page no. and paragraph no.)
1) Center Line of Bench Mark
a. Bench mark vs. punch mark : ± 1.0 mm
b. Punch mark line vs. column center line : ± 1.0 mm
c. Diagonal dimension of column to another : ± 1.5 mm

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2) The variation in dimension between the centres of any two Anchor Bolts within an Anchor bolt Group
shall be equal to or less than 3 mm
3) The variation in dimension between the centres of adjacent Anchor Bolt Group shall be equal to or less
than 6mm
4) The variation in elevation of the top of Anchor Bolt shall be equal to or less than plus or minus 5mm
5) The variation in dimension from the centre of any Anchor Bolt Group to the Column line through that
group shall be equal to or less than 6mm.
Continued to the next page.

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Label this table as: TABLE 1
Item Component Dev iation

1 Deviation of section centreline from

the specified postion

△ = 3mm

2 Deviation of length for Beam

-3㎜ ≦ ΔL ≦ +3㎜

3 Deviation of length for Colunmn

L < 10m L ≧ 10m

-3㎜ ≦ ΔL ≦ +3㎜ -4㎜ ≦ ΔL ≦ +4㎜

4 Deviation in each story

L < 10m L ≧ 10m

-3㎜ ≦ ΔL ≦ +3㎜ -4㎜ ≦ ΔL ≦ +4㎜

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5 Deviation of bending for Beam

e ≦ L/1000 or e ≦ 10㎜

6 Deviation of bending for Column

e ≦ L/1500 or e ≦ 5㎜

7 Gap Between Bearing Surfaces

e ≦ L/1500 or e ≦ 5㎜

Floor Beams Level at each end of

same beam
8
Deviation is Level
△ = 3mm

Maximum deviation relative to base

9
Deviation of lean for Building
e ≦ H/4000 + 7㎜ or e ≦ 30㎜

6.4 Structural Stability

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1) Erector shall, at all times, be responsible for the adequacy and installation of any temporary bracing or
guy cables required to counteract loadings imposed during erection, This responsibility shall also extend
to temporary bracing required to ensure safe and stable conditions of partially completed structural
assemblies.
2) The structure shall be plumbed, levelled and braced to tier by tier before any final bolted or welded
connections are made.
3) After plumbing the structure, all connections shall be completed and bolted to specified torque.
4) Provide temporary shoring and bracing members with connections of sufficient strength to bear imposed
loads.
5) Remove temporary connections and members when permanent members are in place and final
connections are made

6.5 Setting Base Plates

1) Erector shall clean the top of bearing surfaces and the bottom of base plates. Erector shall set and shim
column base plates to correct positions, elevations, and locations as shown on the erection drawings.
Shims or wedges may be used and shall be provided by Erector.
2) Grouting of base plates shall be in accordance with Method Statement for Grouting work of Static
Equipment (S-00-ULF-M-46-003-001)
3) Pour non-shrink grout under base plate to ensure that no void remains. Provide a bearing surface which
is fully supported, flat & level at the correct elevation.
4) Grout shall not be carried out under column base plates until a structure has been aligned, levelled,
plumbed and adequately braced.
5) Before grouting, the space under column base plates shall be clean and free of all extraneous matter.
6) When required on the drawings, anchor bolts shall be tightened to the specified tension. Anchor bolts
shall be fully tightened to the specified tension only after the base plates have been grouted.
7) Tighten anchor bolts after the supported members have been positioned and the plumbed. Provide
wedges and shims, the shims shall be removed after the grout has hardened, and the voids left by the
shim removal dry packed with the same material as original grouting.

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7. Bolted Connections

7.1 General

1) Regarding Connections (Material, Connection Type and Inspection etc.) shall be as indicated by
purchaser as on the erection drawings and as specified other document.
2) All field connections shall be bolted unless specifically noted otherwise on the erection drawings. Bolts
for field connections and related design of joints shall conform with the following:

Description Bolt Type Connection Type Bolt Tight Condition

Label this table as: Table 2 Snug Tight

All other framing Bearing
ASTM A325/M (Refer to Section 7.3)
unless otherwise
High Strength Bolt Friction Bolt Tight
noted
Friction
(Refer to Section 7.4)
Primary ASTM F568/M
Structure Shoulder Bolt or
Long Slotted Hole ASTM A325/M Finger Tight
Bearing
(Expansion Joint) High Strength- (Refer to Section 7.2)
Long Threaded
(To be installed 2nuts)
Ladder, Handrail,
Toe Plates, Posts, ASTM F568M
Bearing Snug Tight
Stair Stringers, Common Bolt
Purlins and Girths

Secondary Permanent fixed :

Structure Field weld

ASTM F568M Removable Plate :
Checkered Plate Counter Sunk Flat Head Bearing Screw Joint
Self Screw Type (using power tool)
Refer to standard
drawings.

3) Where structural joints are made using high-strength bolt assemblies, calibrated wrench pre tensioning
method and inspection methods shall conform to the “AISC Specification for Structural Joints using
ASTM A325 or A490 Bolts” and the contract document.
4) When assembled, all joint surfaces, including those adjacent to the bolt heads, nuts or washers, shall be
free of burrs, dirt and other foreign material that would prevent solid seating of parts.
5) ASTM A490/A490M and Galvanized A325 bolts shall not be reused.

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6) Mechanically galvanized bolts and nuts shall not be intermixed with hot-dip galvanized nuts and bolts.
7) Erector shall colour code, die punch or otherwise mark the ends of imposed torque bolts indicating that
the bolts have been properly tensioned and are ready for inspection.
8) When assembled, all joint surfaces, including those adjacent to the bolt heads, nuts or washers, shall be
free of burrs, dirt and other foreign materials that would prevent solid seating of parts.

7.2 Bolt Torque

1) Installation and inspection torques must be determined or set using Skidmore-Wilhelm (or similar)
devices to establish actual tension, then determine the torque.
2) The purpose of bolt tightening torque shall be achievement of minimum bolt tension.
3) Basic equation to estimate the torque-tension relationship is :
T=kxNxD

Where

T = torque (N·m) k = Nut factor N = Bolt Tension (kN) D = Bolt Diameter(mm)

Nut factor

0.1 : Well-lubricated assemblies (Low)

0.167 : Average
0.25 : Dry or rusty fasteners (High)

7.3 Bearing Type Connection

1) "Bearing-type connections" shall be snug tight condition, unless otherwise shown or noted on the
erection drawings e.g. Finger tight. The allowable loads shall be based on all bolts having threads in the
shear plane.
2) The Snug Tight Condition is defined as “The Tightness attained by either a few hits of an impact
wrench or the full effort of a worker with an ordinary spud wrench that brings the connected plies into
firm contact.”
3) Snug Tight Torque Reference

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Label this table as : Table 3

A325 Bolt Approximate Torque for Snug Tight Condition

Bolt Torque (Nm)

Min. Bolt
Diameter Low Average High
Pretension(kN)
(mm) (0.1) (0.167) (0.25)
70 121 182
M16 91/2
(7.4kg.m) (12.4kg.m) (18.5kg.m)
142 237 355
M20 142/2
(14.5kg.m) (24.2kg.m) (36.2kg.m)
193 323 484
M22 176/2
(19.7kg.m) (32.9kg.m) (49.3kg.m)
246 461 615
M24 205/2
(25.1kg.m) (41.9kg.m) (62.7kg.m)
* The purpose of this table is to give a guideline of bolt tightening at site.

4) Finger Tight (Hand Tight) is defined as “The Tightness attained by a person can tighten a fastener
without a tool.”

5) Expansion Joint(Slotted hole)

Field assembly shall insure a snug fit condition. Nut shall be drawn finger tight as followings.
a. The nuts should be hand-tightened with a spud wrench and then backed off one-quarter turn.
b. And a locking nut or jamb nut should be installed additionally nut not back off further under service
conditions.

7.4 Friction Type Connection (Pretensioned, Slip Critical Joint Condition)

1) “Friction Type Connection” shall be done from snug tight condition to additional bolt tight.
2) One of pretensioning method in Section 7.4 shall be used and which indicated by Purchaser.
3) Friction Type Torque Reference

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Label this table as: Table 4

A325 Bolt Approximate Torque for Friction Type Joint Condition

Torque(N·m)
Bolt Diameter Min. Bolt
(mm) Pretension(kN) Low Average High
(0.1) (0.167) (0.25)
146 243 364
M16 91
(14.8kg·m) (24.8 kg·m) (37.1 kg·m)
284 474 710
M20 142
(29.0 kg·m) (48.4 kg·m) (72.4 kg·m)
387 647 968
M22 176
(39.5 kg·m) (65.9 kg·m) (98.7 kg·m)
492 922 1230
M24 205
(50.2 kg·m) (83.8 kg·m) (125.4 kg·m)
The purpose of this table is to give a guideline of bolt tightening at site.

7.5 Pre-tensioning Method

1) Turn-of-the-Nut Pretensioninga,b Label this table as: Table 5

(AISC Specification for Structural Joints Using ASTM A325 or A490 Bolts, Table 8.2)

Disposition of Outer Face of Bolted Parts

Bolt Lengthc One face normal to bolt Both faces sloped not
Both faces normal to
axis, other sloped not more than 1:20 from
bolt axis
more than 1:20d normal to bolt axisd

Not more than 4db 1/3 turn 1/2 turn 2/3 turn

More than 4db

1/2 turn 2/3 turn 5/6 turn
But not more than 8db

More than 8db

2/3 turn 5/6 turn 1 turn
But not more than 12db

a. Nut rotation is relative to bolt regardless of the element (nut or bolt) being turned. For required nut
rotations of 1/2 turn and less, the tolerance is plus or minus 30 degrees; for required nut rotations of
2/3 turn and more, the tolerance is plus or minus 45 degrees.

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b. Applicable only to joints in which all material within the grip is steel.
c. When the bolt length exceeds 12db, the required nut rotation shall be determined by actual testing in a
suitable tension calibrator that simulates the conditions of solidly fitting steel.
d. Beveled washer not used.

2) Calibrated Wrench Pretensioning Method

a. Engineer will observe operations for the installation and tightening of bolts to determine whether the
work is being performed properly, and will inspect the nut surface for indication of wrench impact.
Bolt tension will be checked, at Owner’s discretion, with an Inspector's Wrench in accordance with
the applicable provisions of Section 8 of the “AISC Specification for Structural Joints Using ASTM
A325 or A490 bolts”.
b. When impact wrenches are used, wrenches of adequate capacity with sufficient air supply shall be
provided by the Erector to perform the required tightening of each bolt.

8. Welded Connections

8.1 General

1) Field welded connections shall be permitted only where shown on the erection drawings, or previously
approved by the Purchaser.
2) Welds shall be made only by welders, tack-welders and welding operators who must be qualified in
accordance with standard welding specification and approved by the Owner.
3) Welding shall conform to AWS D 1.1/M.
4) All welding shall be performed by the manual shielded metal-arc (SMAW), submerged-arc (SAW)
welding processes or the flux cored-arc (FCAW) welding process utilizing self shielding gas.
5) Each weld shall be uniform in width and size throughout its full length. Each layer of welding shall be
smooth and free of slag, cracks, pinholes and undercut, and shall be completely fused to the adjacent
weld beads and base metal. In addition, the cover pass shall be free of coarse ripples, high crown, deep
ridges and valleys between the beads, and shall blend smoothly and gradually into the surface of the
base metal.
6) Butt welds shall be slightly convex, of uniform height, and shall have full penetration.
7) Fillet welds shall be of specified size with full throat and the legs of uniform length. Weld size shall be
minimum 6 mm where not specified.
8) Repair, chipping or grinding of welds shall be done in such a manner as not to gouge, groove, or reduce
the base metal thickness.

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9) All pre-qualified welding procedures to be used shall be referred to the engineer for his approval by a
written procedure specification.
10) Except when the written evidence of a previous qualification test is accepted by the engineer, joint-
welding procedures shall be employed. In executing the work shall be qualified prior to be used in
accordance with section 5 of AWS D1.1/M.
11) Welding shall not be done when the surfaces are wet or exposed to rain, high winds, nor when welders
are exposed to inclement conditions.
12) The size and lengths of welds shall not be less than those specified in the standard drawing and detailed
drawings, nor shall they be substantially in excess of those requirements without the approval of the
Purchaser.
13) The location of welds shall not be changed without the approval of the Purchaser.
14) Post weld heat treatment and preheat, where applicable, shall be conducted in accordance with
applicable codes (AWS D1.1/M) and standards. Records of post weld heat treatment shall be made
available for inspection when requested.
15) After completion of welding, fabricated parts shall be stress relieved in accordance with the applicable
codes and standards.
16) Welding shall not be permitted during inclement weather, unless adequate protective.
17) Qualify procedures and personnel according to AWS D1.1/M, "Structural Welding Code--Steel." Weld
Connections: Comply with AWS D1.1/M for welding procedure specifications, tolerances, appearance,
and quality of welds and for methods used in correcting welding work.

8.2 Filler Metal

All filler metal that has been removed from its original package shall be protected or stored so that its
characteristics or welding properties will not be affected. Electrodes which have been wet shall not be used.
Low hydrogen electrodes shall be dried in accordance with the instruction of the manufacturer before being
used.

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8.3 Preheat and Inter pass Temperature

Prior to welding, the base metal shall be preheated as required to the temperature called for below table.
Label this table as: TABLE 6
Minimum preheats and interpass temperature
Thickness of the thicker part
at point of welding
Welding process
Over 20 mm to
Up to 20 mm incl.
40 mm incl.

Shield metal-arc welding

With other than low None * 65℃
Hydrogen electrodes

Shield metal-arc welding

None * 20℃
With low hydrogen electrodes
* Where the base metal temperature is below 0℃ the base metal shall be preheated to at least 20℃ and be maintained
during welding and all hydrogen welding rod must be kept in a rod oven or a potable rod heater container once its
container is opened and prior to its usage for welding.

8.4 Welding Procedure

1) Arc strikes outside area of permanent welds shall be avoided on any base metal.
2) Before welding over previously deposited metal, all slag shall be removed and the weld and adjacent
base metal shall be brushed clean.
3) Groove welds shall be terminated at the ends of a joint in a manner that will ensure sound welds. Where
possible, this shall be done by using extension bars or run-off plates.
4) Extension bars or run-off plates, if used, shall be removed upon completion and cooling of the weld,
and the ends of the weld shall be made smooth and flush with the abutting parts.
5) When welding is completed, temporary bolt holes shall be plugged with steel, welded and ground
smoothly.
6) Steel backing, if used, shall be made continuously to the full length of the weld, and need not be
removed unless otherwise specified.

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8.5 Welding Qualifications

Welding Qualifications should be according to PURCHASER QM procedure and Consultant Requirement.

1) The Erector shall submit the WPS (Welding Procedure Specification) with PQR (procedure
Qualification Record) to the Purchaser at least two weeks before erection commences.
2) Weld maps/tables should be submitted for approval by PURCHASER.

9. Inspection and Tests

All inspection and tests shall conform to the “Code of Standard Practice for Steel Buildings and Bridges”
published by the AISC and shall be inspected per relevant approved ITP.
Erector should be followed Inspection Procedure for Structure (S-00-TAA-Q-43-019-001)

9.1 High Strength Bolt Inspection

1) Inspection of high strength bolted connections shall be in accordance with AISC “ Specification for
Structural Joints Using ASTM A325 or A490 Bolts”
2) A qualified inspector will be provided by the Purchaser to ensure that all bolting procedures and
complete installation are satisfactory. Inspection by the Purchaser’s Inspector does not relieve the
Erector from the overall responsibilities for the adequacy installation.
3) Inspector will review and observe all bolting operations including :
a. Calibration of equipment and materials by acceptable procedures.
b. Bolting operation by acceptable equipment and procedure.
c. Installation of a washer adjacent to nut or bolt head, whichever is the turned element.
d. Tightening sequence in all connections to ensure that initially tightening bolts are not
loosened by the tightening of surrounding bolts.
e. Condition of bolts as received at the jobsite. Any shipments containing used, corroded,
damaged, or dirty bolts, nuts and washers or load indicator washers shall be rejected.
f. Installation by acceptable procedures where unfair holes are encountered.
g. Special washer requirements of the specification have been followed.

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4) Inspector will observe operations for the installation and tightening of bolts to determine whether the
work is being performed properly, and will inspect the nut surface for indication of wrench impact. Bolt
tension will be checked, at Owner’s discretion, with an Inspector's Wrench in accordance with the
applicable provisions of Section 8 of the “AISC Specification for Structural Joints Using ASTM A325
or A490 bolts”.
5) A high strength bolt connection will be judged as a correct tightening if the average load indicator gap is
equal to or less than that shown in this specification.

9.2 Welding Inspection

1) Inspection of welding shall be performed in accordance with the Structural Welding Code, AWS
D1.1/M.
2) Where the Erector is required to provide test information based on non-destructive inspection, the cost
of these tests will be at Erector’s expense.
3) Where non-destructive testing is required it shall be performed in accordance with applicable AWS
D1.1/M.

9.3 Non-destructive Examination

1) All steel structures shall be dimensionally checked and visually inspected before and after assembly.
2) The following Non-destructive Examination (NDE) are required for structural welding :

• 10 percent of the total number of full penetration and partial penetration butt welds shall be
radiographic or ultrasonically examined 100 percent of the entire length of the weld(s) selected.

• 10 percent of the total number of fillet welds shall be magnetic particle examined 100 percent of the
entire length of the weld(s) selected. If anywhere one weld line meets another weld line, that location
shall be one of the selected.

• When a selected weld is rejected, all welds shall be subject to NDE. In this case, NDE shall continue
until approved by Purchaser in accordance with Purchaser provided method. Then, additional NDE
costs cause of rejection shall be ERECTOR’S responsibility.

• Weld selected to satisfy these requirements shall be selected by ERECTOR’S representative and shall
represent a sample of each welder’s work for each type of weld.

3) ERECTOR shall visually inspect all completed welds.

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4) Procedures and acceptance criteria shall be in accordance with AWS D1.1/D1.1M. Undercutting beyond
the limits of AWS D1.1/D1.1M, surface porosity, and crack-like discontinuities shall be removed to
sound metal and repaired. Weld profiles shall be in accordance with Figure 3.6 of AWS D1.1/D1.1M.
5) In addition, specially indicated on the drawings or any other documents by Purchaser which may require
further destructive or non-destructive testing.
6) All lifting lug connections shall be 100% inspected by ultrasonic method. Procedures and operator
qualifications shall meet AWS D1.1 and be submitted to the Company Inspector for review and
approval. For Skid-mounted equipment with a total lift weight of less than 3000 kg, it is acceptable to
use fillet-welded lugs with dye penetrate inspection.
7) The test results shall be recorded and available for inspection by the Purchaser.

10. Repairs

Erector should be followed Method Statement for Steel Structure Site Repair Works (S-00-ULF-M-46-002-001)

1) Fit-up bolts and drift pins shall not be used to bring improperly fabricated members and parts into place
(springing). Drift pins shall not be driven with such force as to injure adjacent metal areas.
2) Drifting to enlarge holes is prohibited, burning of holes is prohibited.
3) Repairs to correct weld defects shall be made using the same procedure used for the original weld, or a
designated weld repair procedure.
4) The repaired areas shall be re-examined using the same inspection procedures by which the defect was
originally detected.
5) Field welding of non-pressure attachments to equipment that has been ASME code stamped is not
permitted.
6) Coating repair applies to areas where galvanized coating is mechanically and/or accidentally damaged
during the handling and erection process but not limited to touch-up paint for above mentioned types of
rectification at site.
7) Repair of damaged coating and touch-up to galvanized coating shall be in accordance with the Painting
Specification (S-00-TBB-T-32-001-001)

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11. Floor Plate and Grating

1) Holes in grating less than 150mm in diameter shall be cut in the field. All cuts of three of more bearing
bars shall be banded. All field cut floor plate or grating openings requiring toe plate protection or
banding shall be installed as required on the design drawing or other Contract Documents.
2) Field cut openings shall clear the insulation by a minimum of 25mm.
3) Erector shall fasten grating and floor plate as specified on the design drawings. A minimum of four(4)
fasteners per panel shall be used. Grating shall be fastened in place with standard galvanized steel
saddle clips. Clips shall be spaced 500mm on centers maximum at supports. A minimum of two clips
for each support member of the grating shall be required.
4) Grating will be prefabricated sections.
5) Floor plate shall be continuous seal welding.

12. Coating Repairs

1) Touch-up shop primer where required. Touch-up painting shall be applied with brush or airless spray
after SSPC-SP3 cleaning. If the touch-up area is wide and blasting operation is possible, spray coating
method shall be applied after re-blasting.
2) All galvanized bolt assemblies tightened against shop-applied paint shall be painted.
3) All erection damage to hot-dip galvanized coatings shall be repaired by Erector in accordance with
ASTM A780. Cold repair using an organic zinc rich coating is allowed. The dry film thickness shall be
0.05 to 0.08mm (2 or 3 mils) and contain a minimum of 94% zinc dust by weight.

13. Tool and Equipment

13.1 Tools
1) Torque wrench
2) Arc welding machine
3) Oxyacetylene welding machine
4) Grinder & power instrument

13.2 Equipment
1) Crawler Crane 750 Tons
2) Mobile Crane 50 Tons
3) Trailer 30 Tons

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4) Boom Truck 10 Tons

5) Fork-lift 10 Tons
6) Flat Trailer 40 Feet
7) Man basket

14. Safety

14.1 Safety control activity plan

14.1.1 The purpose of Safety education

The purpose is to eradicate risky factors in advance after acknowledging all site condition and make the
work smoothly and enhance the credibility of our company

14.1.2 The principle of safety education

1) Obey safety rule by strong control
2) After installation of facilities which safety first and work afterwards, precede the works.
3) Practice non-accident movement.

14.1.3 Newly recruited workers and general education

1) Daily safety education
2) The risky factors of machinery and safety work methods
3) The usage of safety equipment and protection harness
4) Work safety rules
5) Potential risk
6) Special considerations on this work
7) Samples of accident on this work

14.1.4 The education of newly recruited workers

1) The duties of workers according to Industry safety-health regulations
2) The safety control this site

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3) The goal for non-accident rate and critical points for control
4) Explain accident case
5) The usage of safety equipment and protection harness
6) The goal to achieve for non-accident
7) Safety works rule and counteraction for violation
8) Rewards for excellent workers
9) Performance for safety campaign

14.1.5 Regular education

1) Industry safety-health regulations
2) The harmfulness and risk of work process
3) The improvement of work environment
4) Field safety-health control regulations
5) The samples of safety accidents and the preventions of industrial calamity
6) The history of non-accidents
7) The usage of safety facilities and prevention facilities
8) Standard safety work methods

14.2 Safety control plan

14.2.1 The reinforcement of safety organization

1) The selection of safety control manager and safety staff

2) The establishment of daily safety control protection
3) Check the safety check list
4) Establishment of emergency networks

14.2.2 The reinforcement of education

1) Safety education for 10 minutes in advance of works [Equipment operator, signal man, welder]
2) The information of critical safety factors during works
3) The education of newly recruited workers

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14.2.3 The safety of erection

1) Expand the facilities such as safety net, safety rope and scaffold
2) Daily reminding to wear safety harness
3) Establishment of fire prevention plan

14.2.4 The safety of transportation

1) The installation of Safety boards
2) The installation of safety marks for access roads
3) The installation of noctilucent facilities

14.3 The risky factors of work type

14.3.1 Temporary works
1) Establish work plan after the check of the intervention relationship with other works
2) The grasp of the loading status of dangerous materials and falling items

14.3.2 The access and loading of various materials

1) The check of the collision between nearby facilities and roads for material access
2) Secure safe loading place
3) Check loading place and the intervention with other works

14.3.3 Steel structure erection works

1) Falling-down risky factors during steel frame erection
2) The risks by the falling of using tools, bolt and nut
3) The risks by falling of remnants [flame, slag] during and fire works

14.4 Safety Action

14.4.1 The installation of safety facilities
1) The installation of safety net and safety rope
2) The installation of scaffolding and temporary back board ladder while working at height
3) The prevention facilities of using tools

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14.4.2 The performance of safety education

1) Daily training to prevent risk in advance of works for concerned works
2) Education for the risky factor in field
3) Education for the risky factors especially on special work process
4) Repeated education for safety rules

14.4.3 Other safety actions

1) Arrange everything in order
2) Start works after the checking of risky factor in advance
3) Start works under the supervision of inspector and safety staffs
4) Test operation of crane before transportation of steel materials
5) be familiar to obey safety rule perfectly

14.5 Safety control by work type

14.5.1 Scaffolding works
1) In case of scaffolding works, after the check of intervention relationship with other works by inspector,
start works
2) Start works after the check of loading status of dangerous materials and the termination of
Falling materials
3) Start work after marking things in order

14.5.2 Material transportation work

1) Check material access road in advance
2) Do not transport unreasonably by manpower

14.5.3 Access work for equipment

1) Access should be controlled by presence of manager
2) The top of bottom should be lowed at maximum
3) The access road should be measured correctly in advance.[The wide of access road,
The height of high voltage lines]
4) In accessing, it should be controlled by site manager or safety controller

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14.5.4 Safety rules in the use of equipment

Purchase will ensure that all operating circles for position of adjacent tower cranes are planned and
observed. ( See Appendix 2 )
1) Crane operator should obey below items :
 Check the equipment before work everyday
 Check the driving direction before gearing at right and left
 Check the connection with the main power of crane and confirm the location of wire rope before
operation
 Operate the equipment by the standard signal of appointed worker
 Crane should be operated only by approved operator
 Check the equipment before everyday
2) Crane operator should not drive if the situation is as below:
 In case of extra signal which is over than regulated signal time
 In case signal is not unclear
 In case risky signal lamp or bell ringing
 In case wire rope which is hanging is unsafe or hook clamp status is not good
 In case Men or equipments is located under the hoisting materials
 In case Men is riding on the materials which is transported
 In case movement device or brake device is in bad condition
 Although the weight of material is below limited weight, if there was strange experience while
driving
 If it is considered as a risk
3) If material is not hooked, reel the material completely and continue the work
4) Do not operate controller at the same time [hoisting, horizontal movement, driving]
5) Switch must be off – position during the repair crane
6) Ban temporary repair or operation in case the spare parts of crane have some trouble
7) When materials are hoisted, slowly reel and hoist after confirmation of the weight and balance of
materials
8) Operator should not leave the seat when materials are hoisted or without arrangement
9) Grease should not be attached to brakes wheel
10) Operate the crane after securing wide sight by right position

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11) Hoisting work

 Only approved one can do signal work for the hooking of crane
 Assistant worker should give signal
 The signal man should carry safety hat, whistle and walked-talkie
 When materials are hoisted, give signal after checking rope expanded status
 In selecting wire rope, the weight and counteraction for vibrating should be considered
 Hooked items should be checked and do not use inferior and incomplete items
 Angle for hanging should be within 60 degree
 One line hooking should be avoided. Two or four lines should be hooked
 When hoisting or dropping the goods, men should be located far from it and give signal by keeping
safety distance and the prevent the access of other workers
 Make wire rope or chain unfolded
 After checking hoisting, indicate correctly destination to crane operator
 Supporting should be used by strong wood and metal
 The safety weight of wire rope should be decided within 1/6 of rupture
 When wire rope is hanged at the sharp edge of goods, the assistant things should be added
 When over two wire ropes are used to hang, the same weight should be hanged on each rope
14.5.5 Safety rules during welding
1) Electric weld should not be done by disapproved welder
2) As the arc or electric weld causes disease on eyes, welder and workers around him should wear
preventive goggle for light
3) Safety hat, weld cloth, apron, protective gloves should be used
4) Confirm the rear side of welding especially
5) If the materials are not cooled, pick it by nipper
6) Be cautious of when slag is removed
7) As electricity for welding have a risk of electric shock, so below facts should observed.
 When electric cover is damaged in holder, replace it immediately
 Switch should be off when work is finished or interrupted
 Do not weld wearing moisture gloves, clothes, shoes
 Welding machine should be operated by suitable electric circuit and effective earthing device

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 Do not leave alone after putting electric rod to holder

 When working in moisture or high-heat place, use rubber gloves or rubber shoes
 Damaged cable should be replaced or repaired by rubber or PVC tape immediately
 Electric weld machine should be used with electric shock prevention machine
 When it rains, welding should not be done in outdoors
8) Below factors should be obeyed in dangerous place
 Do not weld near explosion risky area or inflammable
 If welding should be done around inflammable area, fire prevention action should be done fully
[especially preparation for fire extinguisher] and weld at presence of inspector
 Do not stand up suddenly when working in high place. [because the falling may happen due to
dizziness]
 When replacement of electric rod in small area, be careful electric rod not to touch body
 When working at height of 2 meter over, install support board not to fall down in to slag
9) When work is finished, below factor should be checked
 Switch must be off
 Check if any small flames remain
 Reconfirm whether everything is in order and after-work status
 Eyes should be washed inevitably
14.5.6 Safety rules for cutting
1) Gas work should be done only by qualified workers and approved workers
2) Gas container should be installed on well-ventilated place and work place should be selected in well
ventilated areas
3) Before working, check the gas container [controller and gauge] and work tools
4) After wearing work clothes, protection gloves, safety shoes, protection goggle and necessary protection
equipment, start work with tidy clothes
5) Start work after placing extinguisher nearby or checking the location of it
6) When zinc, lead and copper is welded and cut in small areas, hose mask or high quality poison
prevention mask should be wearied and ventilation should be prepared
7) Hose should be in order and be hanged if hanger is available
8) Hose should not be positioned on the floor and should be hung, in case hose is inevitably on floor,
protection cover should be installed

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9) Do not use cooper in acetylene pipe and connection area [for explosion may happen]
10) The rear side should be checked during welding, cutting and trimming
11) To prevent fire and damage by cutting slag or flames, support board should be made in order not to fall
down into slag
12) Adjusting flame should be avoided near oxygen bottle, acetylene bottle and LPG
13) Container should not be influenced by impacting and electric sparks
14) Before opening gas container valve, close by screw and open container slowly
15) By open adjuster and release gas and check leakage status of in connection parts
16) Oxygen and acetylene container should not be used at the status of lying
17) Do not use if liquid is emitted from the beginning
18) When torch is lighted, ignition lighter should be used laying the torch instead of using match, cigarette
light and electric arc
19) When torch is connected with hose, make sure acetylene [yellow] hose should not changed with
Oxygen [green] hose
20) After torch is lighted, do not leave it alone or do not use it as lights
21) Do not paint oil like grease to torch
22) Do not close valve at once, close oxygen valve completely and close acetylene valve
23) Acetylene should be used under the pressure of 1 and 2
24) The tools used in order gas should not be used
25) If explosive objects, oil, inflammables are located near by, welding and cutting should not be done
26) To prevent adverse flow and fire, below factors must be obeyed
 The end of tip during work should not be reached to the materials
 Spatter and slag should not be attached to the end of tip
 Make screw firmly in tightening area
 The flow of gas should proceed normally
 Pressure of oxygen and acetylene should be adjusted well
 Make the rubber hose or installed part of adjuster complete
 When work interrupted or finished, make everything in order after confirmation of fire
 During trimming work, water should not be touched to machines and transformers
 When welding and cutting, it must be confirmed by safety controller

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14.5.7 Safety rules in steel frame works

1) Only staffs can enter in work area and keep off from the hoisting materials and radius of equipment
2) Selected worker wearing marks direct the works
3) Safety harness must be wearied and used completely
4) Machines and tools must be checked by manager daily and get rid of inferior items
5) Hoisting line must be used to equipment and tools
6) When working in high place, arrange worker properly
7) After fixing work allotment and sequence, inform all workers
8) If the weather is bad like strong wind and rain, all worker should be stopped
9) When vehicle enter or exit, control properly so the other third person should not be interrupted
10) Safety net should be installed at first to steel structure
11) Safety net should be installed easy to dismantle
12) By the status of checking safety net installation occasionally, repair properly

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14.5.8 The sample of safety net installation

14.5.9 Safety rope installation sample

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14.5.9 Safety Scaffolding installation sample

14.5.10 Steel Structure – Boiler N. Pressure only

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15. Risk Assessment

RISK ASSESSMENT
(Erection Works of Steel Structure)
SSPP PROJECT

Initial Risk Final Risk

Rating Rating
P-Probability P-Probability
Potential S-Severity S-Severity
Control Measures
Item Activity Accident or RF-Risk RR-Residual
Hazard Factor Risk
R
P S P S RR
F
1) General  Ensure Work permit is available to start the a
ctivity
 Suitable PPE must be worm by the workforce
at all times
 Tool Box meeting conducted for the workforc
3 3 8 2 2 4
e involved in this activity
 Risk Assessment/JSA/Methods Statement to
be available with PTW
 All parties to be briefed regarding Risk Asses
sment, JSA, and Method Statement.
2) First Aid Fire or Injury  Available First aid or Rescue Plan with Ambulance
4 3 8 and to be follow (EAP) plan, with Qualified First Ai 1 1 3
der
3) Manual Personnel Injury  Prior to any material lifted it must be ensured
Handling that the weight is capable of being lifted by in
Failing Materials dividual
1  Adequate stacking of Material
4 4 2 2 4
Tilting of stacked 6  Harmful & Hazardous material must be store
materials & d separately & labeled with correct PPE supp
MSDS lied
 Material handling training to be conducted.
4) Hand Non Standard  Tools to be kept clean & protected against co
Tools Hand Tools; rrosion & damage.
 Any cutting edges must be kept sharp but pro
tected from accidental damage or harm.
Personnel Injurie 1  The hand tools which cannot be repaired shal
s 4 3 1 2 2
0 l be withdrawn from service.
 The correct tools in respect of size, weight an
d duty shall be used to perform a job & no ha
ndmade tools.
 Color coding of hand tools.

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 Doc. No. : S-00-ULF-M-46-001-002
Rev. No. : A

RISK ASSESSMENT
(Erection Works of Steel Structure)
SSPP PROJECT

5) Crane Over turning of  Crane operator must be Licensed in Lo

Operation crane, wrong cal Government and competent perso
slinging n to operate cranes & shall perform dai
ly check for the crane
 Adequate supervision must be present
 Banks man must be present for assisti
ng the crane operator.
 All the lifting gears should be proof loa
d tested and certified prior to being put
4 3 14 in use on site 2 2 4
 Any loads being lifted must have a mini
mum two or more tagline
 Load should not be lifted over the head
s of operatives
 Crane & out riggers must be minimum
of 3 meters away from edge of any exc
avation
 When standing on sand, pads to be pla
ced under outriggers.
6) Rigging Incorrect use of  Ensure that operator and rigger are given
Operation crane or poor safety induction/tool box talking.
3 3 14 2 1 4
operation  Ensure crane operators are trained and c
standard ertified.
Load falling from  All lifting operation should be carried o
insecure slings ut under close supervision.
 Competent rigger and trained bank ma
4 3 10 2 2 4
n to be provided.
 Crane must be selected to suit the job
and be provided with SWL indicator.
Failure of crane  Ensure that there are no persons unde
ropes, slings, r suspended load
shackles, lifting  Check the SWL against the load to be l
devices, etc ifted
 All ropes, slings, shackles, lifting devic
es are to be checked prior to each lift
2 4 12 2 2 4
 These checks are to be carried out in a
ddition to periodical inspection & ensur
e that the equipment is tested
 Supervision in-charge will inspect & ap
prove the lifting equipment prior to any
lifting operations.

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 Doc. No. : S-00-ULF-M-46-001-002
Rev. No. : A

RISK ASSESSMENT
(Erection Works of Steel Structure)
SSPP PROJECT

7) Scaffolding Falling from  Man Basket with Third – Party Certifica

/ Working height, Falling te
Objects  Working platform must be clear from d
at Height
ebris.
4 6 14 2 3 4
 Appropriate hand rails, mid rails, and t
oe boards must be provided.
 Fall protection must be worm as per th
e site condition.
8) Noise / Hearing  Wherever appropriate suitable method
Dust problems: will be adopted to reduce the noise lev
inhalation of el.
dusts
 Appropriate PPE will be made use of w
here the noise level 85dbA
2 3 6  Noise zones to be established. 2 1 2
 Where deemed necessary all cutting a
nd grinding dusts should be controlled
by a mechanical means
 Access roads will be watered adequate
ly i.e water sprinkling to be done on re
gular basis.
9) Night work Fall from height • Sufficient Lightings / illumination to be
installed in strategic locations at site
• All workers to wear reflective vests or
reflective type life jacket
• Personnel to be issued with clear safety
3 3 16 2 1 5
glasses
• Drivers / operators to take rest and stop
Operation when feeling sleepy or tired
• Using two way radio with operator and
rigger for communication.
10) House Accumulation of  On-going work and housekeeping as w
Keeping rubbish & scrap ork plan and maintained at all time.
material 3 3 8 2 1 2
 Housekeeping shall be conducted at th
e end of each working shift with all rub
bish disposed into containers.

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 Doc. No. : S-00-ULF-M-46-001-002
Rev. No. : A

RISK ASSESSMENT
(Erection Works of Steel Structure)
SSPP PROJECT

Instruction:
Risk Factor Matrix
Probability Methodology
Probability Risk Priority
4 – Probable / Likely to occur 4 3 2 1 8-16 High Risk 1. Identify Hazards
immediately or shortly S 2. List Hazard Events
Medium
3 – Reasonably probably – e 4 16 12 8 4 5-7 3. Calculate risk factor with
Risk
Probably will occur in time v initial risk rating
2 – Remote – May occur in time e 3 12 9 6 3 1-4 Low Risk 4. Detail controls and
1 – Extremely remote – Unlikely r Mitigation plan
to occur i 5. Calculate residual risk
2 8 6 4 2
t factor with final risk ratin
y g
6. Enter risk priority
1 4 3 2 1
7. Evaluate acceptability
of risk

Severity

4 – Catastrophic – Imminent danger exists, hazard capable of causing death or illness at wide scale
3 – Critical – Hazard can result in serious illness, severe injury, property and equipment damage
2 – Marginal – Hazard can cause illness, injury or equipment damage but the damage is not expected
to be serious
1 – Negligible – Hazard will not result in serious injury or illness, remote possibility of damage beyond
minor first-aid case

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