METHOD STATEMENT FOR FABRICATION OF STEEL WORKS

The Primary goal of Metle is the satisfaction of customers by meeting his timelines and Quality
expectations. We detail and fabricate our structures as per good engineering practises. We fabricate
every component with utmost attention to quality and detail. Below is our company site erection
process:

1 PURPOSE

The purpose of this manual is to ensure that site erections are carried out according to
specifications and in a safe manner.

2 SCOPE

The scope of this manual shall include:

 Understanding the Engineering Documents like GA drawings, Structural Drawings, Data

Sheets
 Basic sequence
 Site organisation
 Erection Procedure
 Safety procedure

3 RESPONSIBILITY

The Site Engineer and Safety Engineer is responsible for the effective implementation of this
manual on site and shall ensure that:
 The workforce is aware of and implements the relevant standards and regulations.
 Changes in procedures, which become necessary during the erection stages, are agreed by
him and / or design engineer, and that the technical documents are corrected in order to be
consistent.
 Hoisting equipments of suitable capacity and in good condition is available for any
preassemblies which must be lifted.
 Means of access, such as scaffolding, ladders, stairs and platforms, are installed to enable
bolting and welding to be carried out satisfactorily.
 General Personal protective equipment (PPE) are provided to work force. Any PPE required
specific to any special task is also provided.
 Erection at site is carried out as per procedures

4 REFERENCE
 Structural Drawings # S100, 101, 102, 103.
 Shop Drawings # SFM -01 to SFM -12
 Fabrication shall conform to IS-800
 All welding shall conform to IS- 816 & IS -814
 All welding electrodes shall conform to IS 814 / IS 1395
 All structural steel shall conform to IS 2062

5 UNDERSTANDING THE ENGINEERING DOCUMENTS “

Drawings are not to be scaled and only written dimensions to be followed. All dimensions are
in millimetre unless noted on the drawings.

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 Terrace floor layout plan: ( BG-2012-03-IN-0101 )

This drawing shows the general arrangement layout of the terrace floor. This drawing
indicated the locations of Training room, meeting rooms, utility rooms and toilet blocks. This
drawing should not be referred for any structural and dimensional information.

Column and Roof Framing layout: ( S 100 )

This drawing shows the roof framing plan, Pedestal and Column layout and typical column
details. The drawings also show the details of baseplate, anchor bolts and the column
mounting details at B1 and B2

Cross section: ( S 101 )

The cross drawings indicates proposed steel columns and Trusses cross sectional details

Truss sectional details( S102)

This drawing shows the truss elevation details for type 1. The drawings give size of
Rectangular and Square section of vertical and diagonal truss members, top and bottom
chord for Truss-1 and Truss-2. The splice plate details for Trusses are also indicated. The
drawings also provides the details of fixing of Trusses to the columns.

Truss elevation details( S103)

This drawing shows the truss elevation details for type 2,3 & 4. The drawings give
dimensional details of vertical and diagonal truss members, top and bottom chord for Truss-1
and Truss-2. The jointing details at the A Ridge are also shown in the drawings.

Structural member:

The Column, Baseplates and the Trusses are fabricated as per shop drawings. All the Purlins
are fabricated at site locations and installed over the trusses.

6. BASIC SEQUENCE OF ERECTION

The basic sequence for erection have been determined and documented for the project and
are as contained in appendices A, B and C: and shall be strictly adhere to by erectors on site.

7. SITE ORGANIZATION:

 Site shall be adequately identified and project signboard erected before commencement
of project.
 Adequate supply of drinking water shall be provided at site.
 Contractor all risk policy (CAR) for the contract value and for contract tenure and
Workmen compensation policy shall be provided.
 Prior to start of work, arrangement shall be made for medical facilities and personnel to
provide prompt attention to the insured and for consultation on occupational safety and
health matters.
 Hazard Identification and Risk analysis shall be done for the Job. Job safety Analysis shall
be done for majority of the tasks.
 Construction site shall have a muster point for headcount in the case of emergency.

8. ERECTION PROCEDURE

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After the Column and Trusses are ready at the factory, it is followed by erection of structure
members at Site, the erection method statement will set out the procedures for delivery and
assembly including the phasing of the erection, welding and methods of erection of the steel
work.

Delivery and Unloading of materials :

A construction sequence relevant to the particular project shall be agreed prior to delivery of
any material to site, from which a delivery schedule shall be produced. All the structural
materials shall be led to the place of work by using proper capacity mobile cranes. Particular
attention shall be paid while leading the materials to ensure that the materials are
unloaded / placed at their place of use to avoid double handling of materials on site and the
positioning of steel in the wrong location.

Delivery of the steel structures shall be in proper capacity trailer / trucks, the delivery of
materials shall be properly sequenced in order to alleviate site congestion, and minimize
double handling and on-site damage.

Handling of Materials

 When handling individual members the following shall be noted:

 Parts with different reference marks shall not be mixed or packed together.
 On large or heavy parts the lifting points shall be indicated, including where possible the
location of the centre of mass of the component.
 All parts that can be easily damaged shall be adequately protected during transport and
handling.
 Components in the storage area shall be kept off the ground, protected from damp and
dirt by means of sleepers or battens. The area of storage shall be barricaded.
 The electrodes shall be packed in closed and sealed packages or tins: storage shall be in
closed and dry place to prevent condensation and special care shall be taken to avoid
damaging the coating.

Foundations Levelling and Measuring

All the column line shall be marked at site and the terrace screed shall be removed to expose
the mother slab at all the places where the baseplate for the columns have to be mounted.
After the column lines are marked and the mother slab is exposed, the place is cleaned for
any loose particle or dust. Holes of recommended diameter and numbers are drilled into the
existing concrete columns for appropriate depth as recommended by HILTI. A template is
made showing the bolt holes and are properly numbered. The holes are drilled to the base
plate as per template at Site using magnetic drilling mchine. All the baseplates are properly
numbered as per the templates.

Hilti bolts shall be installed in the bolts holes drilled in the concrete column as per the
procedure recommended by HILTI. An inspection of the foundation, to check the levelling and
alignment of the anchor bolts, shall be made before erection of Baseplate commences The
base plates are mounted by providing proper allowance (minimum 25mm from surface level)
for grouting. A fixed levelling point and three fixed alignment points shall be established for
this purpose. Any errors in the foundation identified at this stage, shall be corrected using
packer plates. After setting the base plate to proper levels all the nuts shall be placed on the
anchor bolts and initially hand tightened till they are snug against the base plate, while
tightening the nuts the correct sequential bolt order shall be followed. The Gridline of the
columns along both the axis shall be transferred on to the baseplate. An initial setting time of
minimum 7 Hrs shall be allowed before adding load on the base plate.

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Incase due to column rebar interference while drilling the recommended length of drilling is
not achievable, some rebars (here in Rebar A) in the column close to such bolt holes shall be
exposed. A cut to size Rebar shall be welding to the Rebar ‘A’ along its length and the base
plate. This shall be followed with most of the baseplate to provide additional strength.

Assembly and Erection

Planning for the erection of our jobs commence at the design phase, the steel structure is
erected quickly to programme to the lowest possible cost and safety. Questions concerning
the construction sequence and its effect on stability shall be resolved. The designer shall
position the braced bays in a way that they shall be the first to be erected. The structure shall
be braced and true as the erection proceeds.

Works at a height shall be minimized by the use of sub assembly units where practicable.

Where sub assembly shall be carried out on site, it shall be done at the location in order that
the assembly can be lifted straight off the ground and into position.

During lifting damage shall be minimized on the paint treatment by the use of softwood
packers and to ensure that the load will not slip as it is being lifted and that the sling chains or
wires are not damaged.

Where the structure needs additional rigidity during erection temporary stiffening shall be
used to ensure the rigidity of structure until the permanent connections are made.

Installing Columns:

 The column grid line shall be marked on the baseplate. Columns should be set on
levelling plates, levelling nuts, shim packs, or level finished floors for adequate
transfer of construction loads.

 Attach the column rigging through a bolt hole in the top of the column in the web or
a beam clip. If the column rigging cannot be attached to the column due to the
shape of the column, then a choker may be used provided that a way to prevent the
choker from sliding up the column is in place.

 The periphery columns shall be lifted by using the crane and the inside column
( along the A ridge line ) shall be lifted by usibg Derreck. Adjust the crane’s line (by
signalling the operator) to remain above the column rigging (pick point) of the lift as
column is being raised.

 Once the column is lifted off the ground and the crane/ derreck has the complete
weight, stop the lift until the load settles if required once the load settles, proceed to
signal the crane/derreck operator to move the column into position.

 Lower the column on to the baseplate ensure the column is aligned to the grid line
marked on the baseplate. Use spud wrench / sleaver bars to guide the column into
position. Plumb the column and weld the column on to the base plate.
 Release the weight of the column from the crane/Derreck.
 Before releasing the rigging, make sure column is secure by proper welding on the
baseplate.
 Unstable columns must be guyed or braced as necessary.

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Installation of beams on Columns:

 The Periphery beams/Trusses shall be erected by using crane of suitable capacity

and boom length and all trusses and beams within the periphery line mainly along
the ‘A’ Ridge shall be lifted by using suitable capacity Derreck.
 During the final placing of solid web structural members, the load shall not be
released from the hoisting line until the members are secured with proper welding.
 A competent person shall determine if the welding is sound enough to ensure the
stability of cantilevered members: if more intermittent welding is required the same
shall be done.

Painting

Most of the structures are cleaned and all mill scales are removed and one coat of primer is
applied prior to shipment.

Surface Preparation

After erection of the structures, all the structures are painted with one of coat of primer prior
to application of the finished paints. All the structure are cleaned using light sanding to
remove any rust .

Mixing Paint

 Mix the primer with a high shear mixer in accordance with the manufacturer’s
recommendations to smooth, lump free consistency.
 Mix in the original containers.
 Continue mixing until all of the metallic powder or pigment is in suspension.
 Assure that all of the coating solids that might settle to the bottom of the container are
thoroughly dispersed.
 Mix each subsequent coat to achieve and to maintain a homogenous mixture.

Thinning Paint
 Thin the paint only as recommended by the manufacturer.

Conditions for Painting

Apply paint only on clean and dry surfaces and only during periods of favourable weather.

 Do not paint when the temperature of the air, paint, or metal is below 5 0C and at no time
below that described in the technical data sheet: when the air is misty: or when
conditions are otherwise unsatisfactory.
 Do not paint damp or frosted surfaces or surfaces hot enough to cause the paint to
blister, to produce a porous paint film, or to cause the vehicle to separate from the
pigment.
 Allow each coat of paint to dry before applying the succeeding coat. Follow the
manufacturer’s recommendations for drying time, unless a longer drying time is
required.

Application
 Painting at site shall be carried out by using Brush
 Before paint is applied, clean dust and dirt and other contamination from the freshly
painted surfaces.
 Apply primer and subsequent coats immediately after inspection and acceptance of the
surface.

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  For application for intermediate and finish coats, wet stripe all edges, bolts, welds, rivets,
corners, and other irregularities either by brush or by a separate and distinct spray
operation, prior to the application of the full coat.
 Provide safe access for inspection, as required by the Engineer, prior to application of the
full coat over the striped areas.
 Apply intermediate and final coats to areas of steel that will be inaccessible prior to the
stage of construction that prevents access.

Thickness of Coats

 The cumulative dry film thickness will be determined by the use of a Magnetic Dry
Film Thickness Gauge, or equal.
 Increase the thickness of coating, if directed by the Project- in-Charge.

10 SAFETY PROCEDURE

Safety of the workforce :

Every individual working on site shall take responsibility for safe work practices, regardless of
job title. Safety is every one’s responsibility.
Before start of work, all workers shall attend a structural steel erection best practice review
for the project.
Weekly safety meetings shall be held and the subcontractor shall be kept informed, in
writing, about discussions and issues that may affect safe erection of steel (e.g. weather
conditions (such as wind), access, and site conditions)

Risk Assessments and General hazards

Site safety

There can be assorted hazards associated with working on any site and site regulations as laid
down by the OWNER /Facility Operator should be observed.

Manual handling risks

Equipment and associated items may be heavy and care should be taken when handling
manually. It is generally preferable to reduce any risk by avoiding manual handling altogether.
Then unavoidable, correct lifting procedure should be used. Heavy items will include, but not
limited to, roof and floor plates, stilling wells and rolling ladder . Arrangements should be
made for items such as these to be delivered as close as possible to the intended point of
installation and be moved subsequently as much as possible by machine.

Personnel Protective Equipment

The minimum personal protective equipment is as follows:

 Approved safety helmet

 Approved earplugs
 Safety footwear
 Eye protection
 Gloves
 Overalls
 Respirators

And any other equipment deemed necessary by the specific task involved.

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 Risk of falling

If any installation or activity needs to be done at a height above 2Mtrs, care should be
exercised to prevent personnel falling from height. Scaffolding) Man lifting equipment should
be used for such activity) installation.

Specific hazards applicable to Erection of Steel Structures

Crane and Lifting Equipment

 All cranes and lifting equipment shall undergo relevant test and thorough
examination and certified okay. They shall be operated with the use of
manufacturer’s handbook.
 Only certified operators and trained riggers authorised by the contractor shall be
allowed to operate cranes and lifting equipment.
 Crane / lifting equipment operators and/or safety personnel shall carry out daily
inspections and this shall be entered into the crane equipment register.

Cutting and Welding

 Personnel involved with this operation shall use respirator

 Welding shield shall be worn

Mains Voltages

 Care should be exercised when working with mains voltages (240V or 380 V AC). All
appliances, equipment, and materials used for temporary electrical installations
shall be constructed, installed, protected, worked and maintained, so as prevent
danger
 All work on electrical equipment shall be carried out by, or under the immediate
supervision of a qualified electrical craftsman
 Power in excess of 240V shall be transmitted by armoured cable, which shall either
be buried or strung overhead

Workers Orientation

Prior to starting work, every worker shall attend a site orientation to be informed of and
becoming familiar with:
 Site rules and regulations
 Erection plan and procedures
 Equipment to be used
 Hazard assessment
 Work area and emergency procedures 1including the rescue plan.
 Work areas of other trades and the need to communicate planned work activities to
them when working in close proximity

Lifting and Handling Loads

 Manual handling of loads or materials by workers should be minimized.

 Sub-contractors must provide, where reasonably practicable, appropriate equipment
to help workers lift, lower, push, pull, carry, handle, or transport heavy or awkward
loads.

Housekeeping

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  Store all supplies, such as bolts in proper containers and set away from areas where
they can pose tripping hazards.
 Do not leave loose bolts and nuts lying on steel or on ground.
 Perform ongoing cleanup as required.
 Do not string hoses through high traffic areas or stairs 9nstead, hang the hoses up
to eliminate the hazard.

Steel Fabricator’s Responsibility

The steel fabricator shall be responsible for:

 Providing detailed connection information to ensure that the structure can be safely
erected.
 Providing, where required, safety attachments or anchor points.

Steel Erector’s Responsibility

The steel erector shall be responsible for:

 Ensuring workers are adequately qualified, suitably trained, and with sufficient
experience to safely perform the assigned work.
 Inform the company about access needs to the site specific work areas.
 Pre planning work activities to ensure that workers are not required to work under
unsafe or suspended loads.
 Developing site specific work instructions and procedures that identify access and
area needs
 Ensuring that requirements for moving loads over working areas are met. The
erector must comply with the general and specific requirements of lifting and
handling loads.

Structural Stability
 Ensure that structural stability is maintained at all times.
 Construction loads must not be placed on any structural steel unless such
framework is safely bolted, welded, or otherwise adequately secured.
 Then used, temporary bracing must be in place and properly installed in
con4unction with the steel erection plan to ensure the stability of the structure.
 Temporary bracing can be removed only with approval of competent person.

Rigging
 Careful consideration must be given to the ground conditions and the soil
compaction in areas in which cranes are to be moved and operated.
 If work is to be done or equipment is to be operated in the area of an energized
overhead power line, the employer must contact the power line operator to
determine the voltage of the power line, which determines the safe approach
distance until the power line operator verifies the voltage, the employer must
maintain a safe clearance distance.
 On cranes operating with outriggers, the beams must be extended with the pads
down according to manufacturer’s recommendations. The ground should be
checked periodically for settling, and the outriggers reset if necessary.
 The maximum load rating is not the breaking strength of the piece of rigging  An
erector must ensure that the load rating of the piece of rigging is appropriate (5 to 1
for all below-the-hook lifting devices : 10 to 1 for hoisting of personnel)
 The maximum load rating must be marked on the rigging. If making the rigging is not
possible the load rating should be available to workers on site.

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  Slings must be checked before each use by workers.
 Damaged slings must be permanently removed from service.

Fall Protection

 Workers must use a fall protection system if they may fall 3Mtrs or more, or if there
is an unusual possibility of injury if a worker falls less than 3Mtrs (e.g. falling unto
exposed rebar pointing upward) .
 Workers working on flat roofs and workers engaged in connecting structural
members of a skeleton structure are not exempted from using a fall protection.
 A fall protection plan must specify the:
- Fall hazards at the work site.
- Fall protection system to be used at the work site.
- Procedures used to assemble, maintain, inspect, use, and dismantle the fall
protection system.
- Rescue procedures to be used if a worker fall or is suspended by a personal fall
arrest system or safety net and needs to be rescued.
 Review fall protection plan, including the rescue plan, with workers.

Working at Heights
 Foreman can exercise judgement and shut down all work at his or her discretion due
to wind, rain or any other unusual weather condition.
 Materials must be hoisted using material lifts or ropes and must be secured to
prevent falling off steel. Do not carry materials up ladders.
 Tools must be hoisted using material lifts or ropes and, when the tools are not in
use, they must be secured to prevent falling off steel or from being removed. Do not
carry tools up ladders unless the tools are part of a tool belt.
 Secure and mark covers over open holes.
 Install handrails and kick-plates in conjunction with stair and grating erection, where
required.
 All materials, equipment, and tools that are not in use while aloft must be
contained, restrained, or protected from falling.
 Erectors must protect workers from being struck by falling objects (e.g., an overhead
safeguard strong enough to withstand the shock load of falling objects), or if workers
enter into the danger area, then barricades, warning or signs can warn workers of
the hazards.
 Construction processes below steel erection must be prohibited unless overhead
protection for workers below is provided.
 Safety net can be used to protect workers from falling objects.

Tools
Use of Hand Tools
 Use all hand tools for the purpose intended by the manufacturer.
 Use the right tool for the right job.
 Inspect all tools for defects prior to use.
 Prevent all hand tools from falling (where applicable) by using items such as
lanyards, netting, and chains.

Use of Power Tools

 Power tools must be used in accordance with manufacturer’s specifications.
 Inspect all power tools prior to use.
 Ensure all guards are in place.
 Take damaged tools out of service and tag them for repair
 Use proper personal protective equipment (PPE) while operating power tools
 Ensure portable magnetic drills are tied off and equipped with lock8tight cord ends.

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  Prevent all power tool from falling (where applicable) by using items such as
lanyards, netting, and chains.

Cutting/Burning/Welding Operations
 Secure compressed gas cylinders in an upright position and protect them or locate
them away from falling ob4ects.
 Oxygen fuel systems required a flashback arrestor and a back flow prevention
devices
 A back flow prevention devices is unnecessary in the fuel line of single line torch
systems operating on fuel gas and aspirated ambient air, since the potential for
creating an explosive or flammable gas mixture in the hose does not exist (e.g. tiger
torch).
 Remove combustible material from area, if possible.
 Use fire blankets where required.
 Assign fire watch where required.
 Workers exposed to an airborne contaminant or mixture of contaminants must wear
appropriate respiratory protective equipment.

Equipment
The following are some of the equipment available in our company for the convenient
erection of our steel components

Electrical Equipment and Tools

Generator Nibbler
Grinder Hammer drill
Hole cutter Impact wrench
Electric shear Stapple applicator

Measuring and Survey Equipment

Plumb Theodolite
Automatic level Spirit level
Measuring tape and square

Safety Equipment
Welding hood Goggles
Gloves Safety boots
Safety harness First aid box
Ear Protection Fire Extinguisher

Other Equipment
Welding machine
Oxy –acetylene

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