CBI Eastern Anstalt Telephone Fax :(974) 4981398 Tel: 00974 4539555 Fax: 00974 4981398 ‘Company SNAMPROGETTI Attention: Andrea Tuseano Qatar = Reference QAFCO 5 Expansion Project a Ammonia Tanks Reference: T-CBI-SPS-00059 Dear Sir, Please find attached documents for your approval. lor, Commercial Bank Bids. 7.0. Box. S184 Doha aur Date: 18th Jan. 2009 From — PROJECT MANAGER 5 (Colin Tetchner) Cen: Pages: 1of1 © Method Statement for Tank Wall Construction Rev.02 (Q5-SH-T104,28350-620) Yours sincerely, Colin Tetchner Project Manager Say QATAR ‘AFCO #PROVECT 108 317300 SH Fo ew. zi ) ti RECEIVED DATE: SENT B aie Atty "ACKNOWLEDGMENT RECEIPT ‘Kindly return to us a signed copy ofthis transmittal Page | of 1 BY: aie’ Job Neo Doe. 1D code QATAR FERTILISER COMPANY (F.A.Q) GAFcO as.pr-ceoo.01004 | as-sH-1104 28360-620 Plant WebNa | ___ Doe. No [Bl snamprogetti QAFCO 5 PROJECT 317300 04-RB-E-20070 ‘Acompany otSaivem |” Category Code: Acceptance Code: Fy Poe AHYUNDAI 1 Sh. 1 of 60 | o | ow Document Description CBI Conract No | CBI Doe No @ay Method Statement for Tank Walll Construction | ig1o99 | garco.n-o08 Method Statement for Tank Wall Construction ‘Snamprogetti % Tssved for Consirucion BH | _vs_| cot |teuaNoa o1 Reissue for Approval BH vs CCT |09-NOV-08| 00 For Approval ex | cot | cot a-sePr.oa Rev. Description Prepared | Checked | Approved Date "TS OOCUMENT ISTHE PROPERTY OF CHICAGO BRIDGE & RON COMPAR CBA. ITMAY CONTAIN NFORMATION CESCRSING TECHNOLOGY OMNED BY CBA ANDDoc.No. | : | QAFCO-MS-006 Method Statement for Tank wall Construction aa ‘ aaa 2009 Page No. | : |Page 1 of 20 QAFCO 5 AMMONIA STORAGE TANKS Method Statement for Tank Wall Construction (QAFCO-MS-006 Rev C) Third Issue 02-Jan -09 Second Issue | 02-Nov-08 >lolo | Initial Issue | 14-Sept-08 ments ate EPL EPL EPI Prepared Albert Albert Safety Review wey wBY wey Reviewed & | Remarks | approved byMethod Statement for Tank wall Construction Doc.No. |: [GAFCO-MS.006 Revision | :| ¢ Date 3 January 3, 2008 Page No. | : |Page 2 of 20 SCOPE OF WORK 2. JOB CHECK LIST 3. REFERENCES > }. LOCATION " . WORK PROCEDURES 6. SCHEDULE 7. KEY PERSONNEL 8. CO-ORDINATION 9. EQUIPMENT, MATERIALS and RESOURCES 10. SAFETY 11. JOB SAFETY ANALYSIS: |QAFCO-MS-006 ile Method Statement for Tank wall Construction -{ January 3, 2009 : |Page 3 of 20 L ‘Scope of Work : This method statement describes the execution of tasks involved in construction of the pre-stressed concrete wall for the Ammonia Storage Tanks T-6003 & T-6004. Construction of reinforced concrete wall will be undertaken chronologically from 1* lift to tthe last lift. Each lift of wall will be completed in single concrete pour. ‘Stages of work for construction of wall includes the following : 11 Providing steel reinforcement (including buttress). 1.2 Installation of ducts for pre-stressing. 13 Installation of embedment plates. 14 Fabrication of formwork and suspended platform 15 Erection & Closing of formwork 16 Erection of stair tower 17 Survey works. 18 Pouring of concrete. 19 Curing of concrete. 1.10 Concrete surface finish and filling anchor cone holes. Ait Preparation of construction joint.Doc.No._|: |QAFCO-MS-006 Revision || Method Statement for Tank wall Construction [pate ] January 3, 2009 Page No. |: | Page 4 of 20 La Concrete : Lb Concrete will be supplied from KCQ batching plant and RMQ Umm saeiid will be stand-by Each one has a rated capacity of 90 m3/hr (theoretical) to72m3/hr(physical). In all cases batching plants will use identical materials and produce concrete in accordance with the approved mix design for CSOAE concrete. For each pour we will use 6 numbers of concrete trucks 9 to 10 m’on duty plus two stand-by . Number of pumps with rated output of 90 m3/hour,36 meter to ‘S2meter reach. Cycle per truck is 80 minutes ,giving an output of 40 m3/hr, -10 min batching -25 min travel. -10 min test. -10 min unloading. -25 min travel back, Concreting of lifts of wall will be as per approved construction schedule with CB&I. There will be a hold point on site for measuring temperature and slump and flow as required, prior to discharge every truck. ‘The construction schedule will define the time between each pour. MAR-C-001 Design mix for concrete. MAR-C-002 Hot rolled Yield deformed uncoated re-bars(Qasco QD43) MAR-C-002A Hot rolled Yield deformed uncoated re-bars(Imported by Qasco) MAR-C-003 Galvanized steel wire. MAR-C-005 Release agent. MAR-C-006A Reinforcing bar coupler. MAR-C-007 Sheathing ducts. MAR-C-008 Anchoring system for horizontal post-tensioning. MAR-C-015 Curing compound. MAR-C-016 Expanded metal form. MAR-C-021 Water based concrete surface retarder.Revision |: | Method Statement for Tank wall Construction [pate :| January 3, 2008 Page No. |Page 5 of 20 Doc:No. |: |GAFCO-MS.006 Job Checklist : 21 22 23 24 ‘The following permits will be obtained from competent authorities : PTW (QAFCO 5/CB&z) Messaieed Industrial City Authority Permit for disposal of waste. Manpower with HSE induction 2No Engineers. 4No Foremen. 2No Surveyors. 4No Equipment Operators — With TPI certification 8No Riggers ~ must have valid TPI certification 20 NoScaffolders ~ must have valid TPI certification 20No Labors/20 No helpers/30No carpenters/30No steel fixers. Equipments with TPI certificates Approved materials and suppliers. References : 3.4 Project specification: = Q5-PT-S700.01004 "General Requirements to Civil Works and Structures” = Q5-PT-S700.01005 “General Requirements to Concrete Works” + Q5-SH-T104.28350-239 "Cast In-Place Concrete Construction Specification” = Q5-SH-S700.72004 "Specification for Design of Concrete Structural and Foundations” = MSP104 “Pre-stress Materials and Installation Specification” * Qafco Scaffolding procedure.Method Statement for Tank wall Construction [pate «| January 3, 2009 Doc.No._|: |GAFCO-MS-006 Revision _|:| Page No. | : |Page 6 of 20 3.2 Related Drawings /documents: * Drawing No-164292-508A-01/02 rev O1 + Q5-SH-T104.28350-610" ITP for concrete’ Work will be done in accordance with the above listed documents and project specifications. Location : The location of the work for pre-stressed concrete wall of the tank in consideration is defined within the premises of QAFCO 5 Ammonia Tanks Project. he : a) The reinforcement shall be high yield deformed bars and shall comply with ASTM A615 Grade 60 (420MPa). 5.1.1 During casting of slab starter bars for the walls will be installed as per drawing. The vertical wall reinforcement bars for first lft shall be fixed manually lapped to the starter bars. The horizontal bars shall also be fixed manually for first lift of 3.3m heights. The rebar spacing and lap shall be as per approved drawing. Suitable fall- protection with scaffolding tubes shall be provided along the periphery of base slab during fixing of outer face reinforcement for first lit(see attached sketch). Kicker position and starter bars shall be checked by the surveyor prior to installation of re-bars for first lift, in the event that they are out of position ,a proposal for rectification shall be submitted. 5.1.2 Re-bars will be cut and bent to proper size and shaped as per approved drawings and bar bending schedules at the steel yard and transported to the site. The re-bars will be stored at site in segregated stacks according to bar marks. The re-bars shall be kept clear off the ground by providing a platform rid made of concrete beams. The storage area for reinforcement is shown on temporary facilities layout. 5.1.3 The re-bars shall be kept suitably covered when stored. 5.1.4 The rebar for different lifts of wall shall be fixed manually. ‘The weight of rebar required for each lift is calculated to plan the storage of rebar on wall top and climbing formwork. The manpower required to complete the rebar works in stipulated time period as per schedule is to be deployed.7 [QAFCO-MS-006 il¢ Method Statement for Tank wall Construction :{ January 3, 2009 : [Page 7 of 20 5.15 5.1.6 5.17 5.18 5.1.9 5.1.10 5.111 5.1.12 5.1.13 Rebar installation shall start after the climbing formwork shifting is done from previously concreted lift to the next lift to be concreted. The vertical bars are of typical length and span across two height of two lifts at a time. These bars are designed in such a fashion that fixing of vertical bars is required only on one face in any one lift of wall construction sequence. (This section can be rewritten after IFC drawing). ‘The weight of rebar for second lift for six meter span is 1.4 MT and the weight for six meter span goes on decreasing with increasing height of wall. ‘The length of a shutter panel of Doka formwork is six meter. (This section can be rewritten after IFC drawing). Re-bar will be stored partially inside the wall and partially on the working plat- form (care shall be taken not to exceed the loading limit on the working platform 1KN/m2,see catalogue of Doka). Working platforms will always be maintained free of trips and hazards, avoiding workers to stand on rebars while carrying their work. A normal height worker will fix the horizontal bars first to 1.8m heights, which are easily accessible. Then a working platform shall be prepared with pipe supports fixed on working platforms, secured to already tied reinforcements . Further fixing of horizontal rebar shall be carried out from this working platform, (see attached sketch). ‘The manpower required for stee! fixing is being estimated based on 50 man hours/ton. The actual productivity shall be continuously monitored to arrange the additional manpower immediately as per requirement. ‘Threaded re-bars with ‘Bartec’ approved couplers shall be installed in the temporary opening area( see attached sketch),closing of opening will be subject to another MS. ‘Threading for re-bars will be done in factory. The couplers shall be fixed on the threaded rebar as per manufacturer recommendation. The couplers shall be fitted with PVC screw caps suppiied with the coupler to prevent any ingress of slurry or debris into the exposed end of coupler.(Opening arrangement will be subject to another MS). Cover block of proper size will be used to maintain the required concrete cover to the reinforcement bars. The cover blocks shall be of same grade as of concrete for wall.Method Statement for Tank wall Construction [pate :| January 3, 2009 Doc.No. | : [QAFCO-MS.006 Revision |:|¢ Page No. | : |Page 8 of 20 5.114 To provide movement of personnel from outside platform to inside platform and vis-a-vis the vertical steel bars will be provided with company approved couplers at least in two locations for each lift. Threaded Vertical bar will be fixed to these couplers subsequently (see attached sketch). 5.2 Fixing of pre-stressing conduits : 5.2.1 5.2.2 5.23 5.2.4 Horizontal sheath that will be fixed in position by tying these with extra transverse sacrificial support re-bars tied between inner and outer reinforcement mesh for the wall at regular spacing and at required level. The level of sheaths shall be maintained as per drawing. Grouting ports and vent pipes fixed on ducts will be provided at the proper location as per the IFC drawings of the pre-stressing. Ends of the grouting nozzies and vent pipes will be taken out from the. formwork and protected properly, so as to avoid blocking by concrete and slurry. ‘The conduits will be checked to confirm that they are not blocked with concrete or other debris by using a dolly. For ensuring that the post- tensioning duct is free from obstruction or blockages during concreting dolly passing is required. 5.3 Installation of Embedded Plates : 53.1 5.3.2 5.3.3 Embedded plates will be provided at the locations shown on the relevant drawings. Centerline of each embedded plate will be checked by a calibrated total station survey equipment. ‘The embedded plates will be pressed to the formwork with the help of bolts tightened against the reinforcement mesh. Location of embedments will be checked after concreting ,to verify that they have not moved or displaced. 5.4 Formwork & Scaffolding for Wall : 541 Basic formwork for wall will be DOKA climbing formwork system (see attached design).? ]GAFCO-MS006 Revision |: | c Method Statement for Tank wall Construction [pate | sanuary 3, 2009 Page No. | : |Page 9 of 20 5.4.2. Scaffolding for access tower in two diametrically opposite side will be of DOKA {oad-bearing tower (see attached catalogue). 5.5 Details of formwork for wall : Deflection of formwork is as per attached Doka catalogue. 5.5.1. For proper alignment of the wall formwork 100 mm high kicker will be cast. ‘The radius of kicker will be checked at regular interval and it should be within specified tolerances for tank wall construction as per project specifications. 5.5.2 DOKA dimbing formwork system 150F will be assembled at carpentry workshop. Works will be done as per Doka shop drawings. Doka personnel will supervise the assembly of formwork. 5.5.3 From the carpentry shop, the assembled formwork will be shifted to site and erected in location with the help of tower cranes erected at site. 5.5.4 The proper curvature for the tank wall will be maintained with the help of horizontal planks sawn to desired curvature, which will support the DOKA wooden beams. 18mm faced plywood will be screwed to wooden vertical beams. 5.5.5 The shutters will be cleaned and shutter release agent will be applied on it before closing of formwork. Both faces willbe tied together rigidly with tie rods at spacing and heights indicated on Doka drawing. For the first lft, the shutter bottom is positioned against the kicker and supported with props (see attached detall). 5.5.6 Inclined props supported on base slab will support first lift. For support extra rebar will be cast in base slab, which will be cut later (by using suitable approved material) 75 mm deep and surface repaired as per approved procedure (see attached detail). 5.5.7. Positioning cone with stop anchor will be placed in proper location in the first lit formwork. After stripping of formwork the positioning cone shall be removed and climbing cone will be fixed in that position. The dimbing formwork for next lift is supported on dimbing cones. Formwork will be stripped and lifted to the next layer after 3 days or if the concrete reaches a minimum strength of 40% of the required 28-days cube strength. These concrete strength will be established after crushing extra cubes taken during concrete pouring of a particular lift. 5.5.8 The details of removal and fixing of formwork for next lift is attached in Doka catalog. 5.5.9 The whole assembly will consist of the following :Method Statement for Tank wall Construction [pate | January 3, 2008 Doc.No._| = [GAFCO-NS006 Revision |: | ¢ Page No. | : |Page 10 of 20 a) b) Vertical waler and sliding spindle. Climbing bracket 150F. ‘The scaffold bracket L The lower platform. Supervisor from Doka will visit site and instruct concemed personnel as and when required. This climbing process will be continued till the 12" lift. Details of formwork is attached in Doka catalog. ‘The formwork for buttress has to be fixed after connection of PC ducts to anchorages and fixing of bursting reinforcement. The details of corner panels of buttress formwork is explained in Doka shop drawing. ‘See attached details of formworks for Wall lifting. 5.6 Stair Tower ; 5.6.1 5.6.2 5.6.3 5.6.4 5.6.5 5.6.7 5.6.8 5.6.9 ‘Two independent stair towers will be erected for access to the climbing formwork assembly in both half of the tank wall. ‘The stair tower will be made of DOKA scaffolding system. Details of stair tower assembly will be as per the details shown in Doka catalog. ‘The stair tower will be anchored to the wall by means of anchoring shoe at least every 5 Nos. of frames erected. Erecting additional modules for successive lifts will. extend the stair tower. Concrete base will be provided for the stair tower on compacted sub-grade. Drainage shall be ensured around the base to keep it in dry state always. ‘Secured and safe connection will be provided between stair tower and climbing platform with handrails and toe guards. Only certified scaffolders will be used to construct and dismantle the stair tower. 5.7 Survey works :Method Statement for Tank wall Construction [pate :| January 3, 2009 Doc.No._|: |GAFCO-MS-006 Revision | :| ¢ Page No. | : |Page 11 of 20 57. 57.2 5.7.3 57.4 On completion of the base slab, variations in cross-section and levels shall be checked and the center point for the tank will be established. The survey works shall be carried out from this reference point. Total Station will be used for survey works along with any other calibrated survey equipments required. ‘The survey results shall be recorded in proper formats and produced for verification prior to concrete. Post pour survey shall also be carried out for wall and embedment’s. ‘The formwork radius shall be checked at center and edges of each panel at the top, middle & bottom levels of lift. 5.8 Pouring of concrete : 5.8.1 5.8.2 5.8.3 5.8.4 Stage wise inspections as per approved ITP’ will be carried out during the progress of works and final approval will be obtained from the sub-contractor, contractor and Company before starting the concrete pour for a particular section. If the concrete does not start within 24 hours of approval, the approval shall be sought again. Cleanliness of formwork and reinforcement shall be ensured. The final leaning of debris and dirt etc. shall be done with compressed air by opening shutter. Stand by compressor will be available at site. ‘The construction joint shall be kept saturated but free of standing water during pouring of concrete. ‘The concrete for complete ring shall be poured in one continuous operation. Suitable backup arrangements for concrete shall be available to meet any breakdown of batching plant. ‘The method of placing concrete in layers is explained in the attached sketch, each layer of concrete will be covered within 30 minutes (see calculation on ‘sketch to prove the covering of layers within 30 minutes). Adequate planning to contro! the movement of trucks towards the right pump should be well administrated on site to avoid formation of cold joint inside wall. Crews should be well organized and conduct pre-pour meeting to avoid problems on site. Provision of emergency stop-end should be provided in case any failure in supply of concrete occurs, by inserting extra rebars in the construction joint made.Method Statement for Tank wall Construction [pate | January 3, 2009 DocNo. |: GQAFCO-MS-006 Revision | :| C Page No, |: |Page 12 of 20 5.8.5 5.8.6 5.8.7 58.8 5.8.9 5.8.10 5.8.11 5.8.12 5.8.13 5.8.14 5.8.15 The concrete will be delivered to site in transit mixers capable of keeping the concrete in workable and homogenous condition. ‘The maximum height of drop of concrete shall not be more than 1.5 meter during placement of concrete, by using flexible hose connected to the flexible hose of the pump. Appropriate precaution during hot weather concreting shall be taken. Reinforcement and formwork shail be sprayed with water. Preferably the concreting shall be planned avoiding afternoon hours when the temperature is above or expected to rise above 35°C.The concrete supplier shall take necessary precautions to control concrete temperature below the maximum permissible limit(refer to CB8d specification Q5-SH-T104.28350-239). Repair of cracks shall be made as per approved repair procedure. Re-dosing with admixture or addition of water shall not be done at site to improve workability of concrete. ‘The vibrators shall not be used to flow the concrete. Vibration into comers and around embedment's shall be done carefully to avoid displacement. Each lift of concrete pouring consists of 290 m? of concrete except first and second lift where 1* lift equal to 640m? and 2 lift equal to 405m*. Likely pumping rate of concrete in wall will be 30 to 40 m3 of concrete per hour, which is well within the limits of the batching plants. For pouring, 4 nos. mobile concrete pumps of 42-meter boom will be used for first 3 lifts. For each lift concrete pump locations is For each lift of the walls the position and the reach of the concrete pump booms will be demonstrated prior to the commencement of the concrete pour. Concrete will be poured in layers and the rate of rise in formwork shall be restricted to one meter per hour as per Doka design. The maximum thickness of layer shall be 40cm to ensure proper consolidation, controlled by gauges graduated in 40 cm step. For each concrete pump in operation, two numbers of electrical vibrators, frequency 50/60 hz (one and a half inch and one two and a half inch) will be used (plus one spare vibrator for each pump) Al vibrators will be checked and ensured that they are in perfect working condition with one spare available/pump.+ |QAFCO-MS-006 i] ¢ Method Statement for Tank wall Construction [pate | January 3, 2008 Page No. |: |Page 13 of 20 5.8.16 The tie rod holes shall be filled with approved Non-shrink Cementitious Grout(refer to repair procedure). 5.9 Curing of concrete 5.9.1 Formwork of the wails will be removed 3 days after concrete pouring, however it can be stripped at earlier ages if the concrete is at least 40% of the 28-days cube strength, care shall be taken to avoid damage to either fresh concrete or formwork, any damage to either concrete or ply wood will be repaired prior to proceeding to the next lift. 5.9.2 Directly after removal of shutter curing compound will be applied on vertical ‘concrete surface (MSDS shall be available on site prior to application of curing ‘compound, and applicators will be kent informed on the hazards that could be encountered during its application).Curing by water will start immediately after application of curing compound. Unformed surfaces will be continuously wet up to 14 days from day of pouring.(Heat of hydration is addressed in a separate MS), 5.9.3 The same process will be continued for the subsequent stages of concrete pouring, till the final lift is achieved. 5.9.4 Curing will be confirmed for 14 days as per project specification. 5.9.5 Water of same quality same as concrete mix will be used for curing. 5.9.6 Curing water will be at ambient temperature. 5.9.7. Sprinklers attached to the suspended platform will keep the unformed surface wet for 14 days ,attached to each particular shutter and attached to each other by flexible hose. 5.9.8 Freshly placed concrete will be covered with hessian and polythene sheeting ‘as soon as conditions permits. 5.9.9 Heat of hydration trials will be addressed in a separate MS. 5.10 Preparation of construction joint : 5.10.1 Laitance and slurry will be removed by water jetting after application of a surface retarder on the construction joint, (after initial set of concrete)refer to specification Q5-SH-T104.28350-239 clause 3.13 item C and D. Projecting reinforcement will be protected by plastic pipes. 5.10.2 Horizontal construction joint will be cured by wet hessian cloth. 6. Schedule ;Method Statement for Tank wall Construction [pate Doc-No. |: [QAFCO-MS-006 ile January 3, 2009 Page No. | : |Page 14 of 20 Revision 61 Necessary permits shall be taken to cover hours when the work will be performed = 0600 hhrs to 1800hrs. and 1800hrs. to O600hrs in case of night shift works and/or overtime works, oe ‘As much as possible ,resources will not be shared between the two tanks. Key Personnel : 74 Following are the responsibilities of the personnel to be assigned for construction of wall. Manpower with HSE induction ‘Site Manager - shall be responsible for overall monitoring and control of construction activities. Sr. Site Engineer ~ shail report to Site Manager ~ shall be responsible for execution and implementation of all site activities related to this procedure. - shall be responsible for organization of concrete pouring. - shall be responsible for coordination with other subcontractors for interfacing activities. - shall be responsible for equipment deployment and taking measures to achieve production targets. - shall attend the daily progress meeting with CB&d. ‘Site QA/OC Manager: - shall report to Site Manager - shall be responsible for documentation of activities as per approved checklist and ITP. shall monitor all follow-up of testing by third parties.(Doc.No. [= [QAFCO-MS-006 Revision |: | ¢ Method Statement for Tank wall Construction | pate 2{ January 3, 2009 Page No. | : |Page 15 of 20 Site Engineer ~ shall report to Sr. Site Engineer. ~ shall be responsible for execution of tasks assigned. ~ shall be responsible for controlling and deploying manpower for the assigned activity. - shall be responsible to control foremen to implement safe working method. - shall report the daily progress and constraints. ~ shall be responsible for supervising concrete pour. Engineer QA/QC - shall report to Site QC Manager - shall be responsible for contro! and inspection of activities as per approved checkdist and ITP. ~ shall perform the pre-concrete placement and post pour inspection. Surveyor -Shall report to site engineer . -Shall be responsible to produce survey reports of pre-pour and post pour inspections. Foreman - shall report to Site Engineer. - shail be responsible for all reinforcement works. - shall be responsible for formworks. ~ shall be responsible for concrete surface finish and repair works. ~ shall be responsible for supervising the concrete pour. ~ shall be responsible for fixing of post tensioning ducts and anchorages.Method Statement for Tank wall Construction [pate Doc.No._| : [QAFCO-MS.006 Revision | :| ¢ :{ January 3, 2008 Page No. | : |Page 16 of 20 ‘Scaffolding & rigging foreman - shall be responsible for erection and extension of Doka access stair tower. - shall sign the weekly inspection sheet for stair tower. - shall be responsible for erection works. - shall be responsible for inspection of lifting tools and tackles before start of work, - shall be responsible for providing and maintaining proper access to climbing platforms and walkways. ~ shalll ensure compliance of safe working methods. ‘Safety Supervisor ~ shall report to Safety Officer. - shall be responsible for monitoring and implementing the compliance of safe working methods. - shall be responsible for dissemination of information on safe working methods. - shall be responsible for conducting toolbox talks. QAFCOS / CB&I authorities shall be contacted for the necessary issuance of work permits. All works to be undertaken shall be coordinated to each discipline to lear any interface regarding the activities. 91 ‘The following plant & machinery will be deployed for the work : 2.Nos. of Tower crane to be located at each tank. Capacity of tower cranes and effective lifting radius up to 2.6 tons at 50m span, 2No Mobile cranes 25 Tons/50Tons (shared between the two tanks) Bar bending and cutting machine Mechanical & carpentry toolsMethod Statement for Tank wall Construction [pate | damuary 3, 2008 10. 10.1 10.2 103 10.4 10.5 10.6 10.7 108 10.9 10.10 10.11 10.12 10.13 ‘DocNo. |: |QAFCO-MS-006 Revision | :| ¢ Page No. | : |Page 17 of 20 Hand tools. 3 to4 No Mobile concrete pump36m to 52m reach and 6No to 8No concrete ‘trucks(8 to 9m3 capacity) for pouring concrete. Water tank and pump for curing. Level and Total Station survey equipments, Vibrators for compaction of concrete (2per pump+istand-by per pump). Pump & Accessories for water jetting. Gas cutting and grinding machine Lifting tools and shackles Welding machines Permits will be obtained from competent authority to cover works under clause 6.1 of this method statement. All works will be done under strict supervision of Site Engineer and Safety Supervisor. All personnel will have proper PPE including safety body harness. All lifting equipments will have third party certificates and will bear the correct monthly color codes conforming with QAFCOS and CB&d safety precautions. Area within the working radius of the crane will be barricaded. All equipments will have inspection prior to use in site All mobile and lifting equipments will be operated by licensed operators. All hand tools will be used under supervision of experienced foremen. All precautions as per the job safety analysis will be followed at site One wind speed indicator calibrated and with current certificate will be installed over the tower crane(s) to access safe wind speed limit during lifting operations, The operators of tower cranes will have walky-talky / mobile phone for intemal communication. Only trained scaffolders will be used. Supervisor from Doka will provide all necessary instructions to the site personnel. Base of scaffold tower will be compacted and concrete apron will be provided for the base.7 [QAFCO-MS-006 Revision | : | ¢ Method Statement for Tank wall Construction [pate :{ January 3, 2008 Page No. | : |Page 18 of 20 a. 10.14 10.15 10.16 10.17 10.18 10.19 Scaffold pins will be locked with wire. Handrails will be provided on both side of the stair tower. Safety netting will be provided in handrails. Waste dumping will be done as per MIC guidelines All the equipments will be in good working condition and will be inspected by ‘competent authority to control noise. ‘Two qualified first-aiders will be present on site per shift. Job specific tool bax talk s will be conducted on daily basis. Job Safety Analysis :(Doc.No. |= [GAFCO-MS-006 Revision | : | ¢ Method Statement for Tank wall Construction [pate :| January 3, 2009 Page No. | : |Page 19 of 20 JOB AND SAFETY ANALYSISKETTANEH ETTANEH CONSTRUCTION WAL. AMMONIA STORAGE TANKS FOR QAFCO 5 JOB SAFETY ANALYSIS ‘QAFCO 5-JSA-MS-006 Date: 03 January 2008 Rev. C ‘Task Name: TANK WALL CONSTRUCTION Description of “Task Step PXS=R Hazard Potential incident ‘Who or What Might be Harmed Control Measures / Recovery Measures Residual Risk Action Responsible Party | “L.Gutting and Transportation of Reinforcement steel 2X3=6 4.1 Cut injury and Eye injury -workmen Li People will use contractor approved PPE to protect ‘themselves against cut injury and eye injury during cutting with erinder, 1.1.2 Certified Electrician shall be stationed on site and must be available if needs arises. 1.1.3 Maintained Good Housekeeping practices around the work areas; remove all left over or excess cut rebar before leaving and maintain work areas in a tidy __manner. vG=3 Kettaneh/CB&d 2K2=4 1.2 Ufting load induced ‘injury -workm -mate equipment T21 _ Rebars will be lifted and moved with certified lifting equipment and shackles. 1.2.2 Experienced riggers will be used during lifting operations. 1.23 Certified riggers and banksman shall wear hi-visibility vest. (color RED for Riggers and GREEN for banksman).. 1.2.4 Barricade by yellow and black tape will be provided around lift radius of tank (Sm dia.) 1.2.5 Use of tag line will be ensure to control the load. 1K262 Kettaneh/CB& Page 1of9KETTANEH KETTANEH CONSTRUCTION W.LL [AMMONIA STORAGE TANKS FOR QAFCO 5 JOB SAFETY ANALYSIS QAFCO 5-JSA-MS-006 Date: 03 January 2008, Rev. C ‘Task Name: TANK WALL CONSTRUCTION Description of Task Stap PxS=R Hazard Potential Incident ‘Who or What ‘Might be Harmed Control Measures / Recovery Measures Residual Risk ‘Action Responsible Party 2X3=6 1.3 Storage of reinforcement bars on climbing formwork assembly 131 132 133 Storage should be at the designated area Weight of rebar should be within permissible limit as specified crane certificate. Experienced foreman will supervise to ensure proper stacking of materials. 13-3 Kettaneh/CB&i 2Formworkand | scaffolding of wall | 2356 2.1 Fall of materials Zaid 242 243 244 245 216 247 ‘Approved and 3” party certified riggers will be used during lifting operations. All scaffolding works will by done by 3" party trained and CMS&A approved scaffolders. Appropriate certified sling with updated color coding. Loading of tower crane will be within limits. Identifying weight of the load by tagging or marking in case of critical loads. Provision of safety nets will be ‘made on the platform. All persons working on height must used approved type of full ‘Safety Body Harness with 2 lanyards and must be 100% Tied Off on a secured anchor point . 1353 Kettaneh/CB&! Page 20f9KETTANEH [KETTANEN CONSTRUCTION W.L.L. AIMIMONIA STORAGE TANKS FOR QAFCO 5 JOB SAFETY ANALYSIS QAFCO 5-JSA-MS-006 Date: 03 January 2008 Rev. C ‘Task Name: TANK WALL CONSTRUCTION Description of Task Step PxS=R Hazard Potential Incident ‘Who or What Might be Harmed Control Measures / Recovery Measures Residual Risk. ‘Action Responsible Party 224 2.2 Fall of persons 221 2.22 2.23 2.24 225 All persons working on height must used approved type of full Safety Body harness with 2 lanyards and must be 100 % Tied Off ona secured anchor point. Working of scaffolding and formworks will be allowed only after these are secured properly and with green tag. Safety netting to be provided to all handrails on working platform. ‘Maintain Good Housekeeping practices: remove all left over ‘materials from wall and roadways. Properly stack and de-nail used formworks and other construction materials. 222 Kettaneh/CB&d 2.3 Swinging of suspended load 234 2.3.2 Lifting operations must not be done during high wind velocity at 27 knots. Lifting operation to be done supervision of experienced, certified and approved rigger. Foreman to be responsible in ensuring safety compliance in the work. 1353 Kettaneh/CB&s 2x3=6 24 Slip of anchorage >workmen -materials 241 Formwork will be installed on anchorage made by trained and DG=3 Kettaneh/CB&I Page 3 of 9{ | KETTANEH {KETTANEH CONSTRUCTION W.LL. AMMONIA STORAGE TANKS FOR QAFCOS JOB SAFETY ANALYSIS QAFCO 5-JSA-MS-006 Date: 03 January 2008 Rev. C ‘Task Name: TANK WALL CONSTRUCTION Description of ak | TaskStep PxS=R Hazard Potential incident Who or What Might be Harmed Control Measures / Recovery Measures Residual ‘Action Responsible Party 242 243 24.8 245 competent persons only. Anchorage must be done as per recommendation of formwork manufacturer. Competent supervisor to counter check anchorage installation. Proper anchor assembly must be provided. Anchorage must be done under supervision of well experienced foreman for the formwork. system before allowing any person to use the same. | 2x2=4 | 2.5 Pull offanchorage -workmen -materials 251 25.2 253 Concrete should be strong ‘enough to sustain the anchorage (20N/mm*) Enough bearing around should be available. For anchorage manufacturer's recommendation must be followed. 1222 Kettaneh/CB&d '3.Concrete pouring 2x3=6 | 3.1 Manual handling -workmen. -materials Bal 312 Personnel placing concrete will wear suitable approved type of hhand cloves, footwear, face and eyes protection. Trained and authorized personnel under close 11353 Kettaneh/CB& Page 4 of 9KETTANEH KETTANEH CONSTRUCTION WALL AMIMONIA STORAGE TANKS FOR QAFCO 5 JOB SAFETY ANALYSIS QAFCO 5-JSA-MMs-006 Date: 03 January 2008 Rev. c ‘Task Name: TANK WALL CONSTRUCTION Description of ‘Task Step PXSER Hazard Potential incident ‘Who or What Might be Harmed Control Measures / Recovery Measures Residual ‘Action Responsible Party 3.13 supervision will operate plant and equipment used during concrete pouring. Wash facility to be provided for workers. 23-6 3.2 Defective plant/equipment -workmen -equipment Bad 3.2.2 3.23 Al plant and equipment will carry current certification and be ‘maintained in a safe condition. Defective plant/equipment will bbe removed from service and effective remedial actions taken. Only approved plant/ equipment will be used. 1353 Kettaneh/CB&i 2x2=4 | 2.3Fcting Materials 1 | -workmen -materials Bad 3.3.2 333 334 ‘Slinging and lifting operation will be carried out by trained/certified personnel. Certified Riggers and Banksmen shall be wear hi-visibility vest. (color RED for Riggers and GREEN for banksman). Un-authorized person will be prohibited from entering areas where concrete placing activity is being under taken. Maintain Good Housekeeping, all loose material will not be kept on platform. 12-2 Kettaneh/CB&! Page 5 of 9KETTANEH KETTANEM CONSTRUCTION WL. AMMONIA STORAGE TANKS FOR QAFCO 5 JOB SAFETY ANALYSIS (QAFCO 5-ISA-MS-006 Date: 03 January 2008 Rev. C ‘Task Nam 'ANK WALL CONSTRUCTION Description of Task Step PxRS=R Hazard Potential Incident ‘Who or What Might be Harmed Control Measures / Recovery Measures L Residual Risk ‘Action Responsible Party 2X36 3.4Heat Stress from wearing protective equipment in hot weather Provision of sufficient cool drinking water and shelter... Heat stress to be discussed before start the job. 1x3=3 Kettaneh/CB&i Heat stress management -workmen Eve 342 Frequent break during hot weather, rest interval to be implemented as per heat index.(depends upon amt conditions). Heat stress to be discussed before start the job. vG=3 Kettaneh/CB& 3X39 3.5 Electrocution workmen materials 35.1 35.2 Suitably protected CTE Approved Electrical supplies and frequent portable appliance testing. Certified Elecrician shall be stationed on site and must lable if needs arises. 1359 Kettaneh/CB&d 2K2=4 3.6 Contact with moving Machinery or Vehicles -workmen -materials. vehicles 361 3.6.2 3.6.3 ‘All machinery movements to be control of a qualified banksman/slinger. Wearing of high visibility clothing. Minimise reversing movements, plant fitted with flashing beacons, reversing alarms and cc. ax2=2 kettaneh/CB& Page 6 of 9KETTANEH ETIANEH CONSTRUCTION W.LL ‘Task Name: TANK WALL CON: (STRUCTION AMIMIONIA STORAGE TANKS FOR QAFCO 5 JOB SAFETY ANALYSIS ] QAFCO 5-1SA-MS-006 lieerery |oos EE Description of Task Step PXS=R Hazard Potential incident Who or What Might be Harmed Control Measures / Recovery Measures Risk ‘Action Responsible Party Dermatitis and concrete burns and cement with eyes “Awareness of the risk. | Provide suitable gloves and protective clothing and barrier cream. Provide suitable washing facilities. Provide eye wash stations close to the area. 22-4 38 Nowe workmen 3.8.1 Provision and enforced wearing of high quality ear defenders e.g. ear muff and ear plug. 1-2 Kettaneh/CB&i Das 3.9 Slips, Trips and Falls workmen materials 'B.iProvide access routes. | Good Housekeeping, Edge protection where there is a |___tisk of falls at edges or openings. ve3 Kettaneh/CB&i ‘4. Concrete Pumping and Placement Da=6 41 Splash Back -workmen materials -equipment “4.1.4During Pumping Operations Operatives will ensure the Flexi pipe willbe as close/low to the surface areas asis reasonably Practicable to avoid concrete splashes, De=3 Kettaneh/CB& 42 Concrete Burns Contact Dermatitis workmen 4.2.1 Awareness of the risk Provide suitable gloves and protective clothing and barrier cream. Provide suitable washing facilities. Provide eye wash stations Kettaneh/CB&l Page 7 of 9AMMONIA STORAGE TANKS FOR QAFCO 5 | QAFCO 5-1SA-MS-006 KETTANEH | Date: 03 January TermwenconTeucnonwt | JOB SAFETY ANALYSIS. oad ev. ‘Task Name: TANK WALL. CONSTRUCTION Description of ai ‘Who or What Residual | Action Responsible TeckStey | PXS=R Hazard otentiatincident | sithcpe armed | Control Measures /RecoveryMeasures | NE) fae 5. Concrete 5.1 Unauthorized access Suitable fendi Caring Until concrete has Consider use of supewision at 1x262 | Kettaneh/CB&I hardened (drowning in| -workmen Other times. deep pour) 2x04 52.1 Rogs/plastics and domestic waste | to be disposed of in designated | 5.2 Aags.and Plastic workmen skip/bin and removed by 2x22 | Kettaneh/CB&I materials approved authorized waste contractor. 6. Waste ie G41 Drip trays to be used with generators produced and other plant where there may be from work. a tkelinood of accidental spilage. workmen Spilage contaminating land shall be ? 6.1. Fuel Oi'Spilage materials disposed of in accordance with local ans Environmental Laws and under aed | cece ceel advise from Environmental ream. 7. Ba=4 | 7d Fire Hazards 71 Combustible and farvmable Environmental | workmen materials tobe stored in accordance Protection & | materials With CoSHH/MSDS requirements and | local regulations. a2 Seen ae | 7A2 Fire Extinguishers strategically : | placed, adjacent to generators and mobile plant, 7.13 NoSmoking except in designated Page 8 of92