Preliminary

Erection
Method of Coal
Shed Building
CFSPP-1 SULUT 2 X 50 MW
PROJECT
Content of Erection Method
1. Preparation
2. Erection method
3. Repair procedure

2
1. PREPARATION
1.1 DESIGN PREPARATION

• Project Name : PLTU Sulut-1 Coal Shed

• Building Type : Single Layer Pipe Truss
• Width of Shed : 116 m
• Length of Shed : 60 m
• Height of Shed : 35.5 m (top of roof)
• Height of Pedestal : 4m
• Total Height : 39.5 m (top of roof)
• No. of Column : 15 Column
• No. of Grids : 11 Grids
• Total Weight : 267.253 kg
• Weight/Column : 7.068 kg
• Weight/Grid : 17.870 kg

3
 1. PREPARATION SEGMEN-4
1.1 DESIGN PREPARATION Truss 7 (x2)
Berat 2,25 Ton
SEGEMEN-3
Truss 8, 9, 10 (x2)
Berat 5,7 Ton
SEGEMEN-3 SEGMEN-2
Truss 4, 5, 6 (x2)
Truss 11 & 12 (x2)
Berat 5,7 Ton Berat 5,6 Ton

SEGMEN-2
Truss 2 & 3 (x2)
Berat 5,6 Ton

SEGMEN-1 SEGMEN-1
Truss 13
Truss 1
Berat 2,16 Ton Berat 2,16 Ton

4
1. PREPARATION
1.2 TEMPORARY SUPPORT PREPARATION

TS 1 TS 2 TS 3 TS 4

5
1. PREPARATION
1.2 TEMPORARY SUPPORT PREPARATION

The model
calculated only TS.3
which is most
highest and most
heavy the loads and
represent the other
supports

TS 3

5
7. Prepare Temporary Support
Calculation of temporary support with staadpro Plan &
View model.

1
2

A TS.1 TS.2 TS.2 TS.1 B

14
7. Prepare Temporary Support
Calculation of temporary support with staadpro Plan &
View model.
Group 4

Group 3

Group 2

Group 1
TS.1

TS.2

TS.2

TS.1

15
7. Prepare Temporary Support
Calculation of temporary support with staadpro According
to sequences (group).
Group 4

Group 3

Group 2

TS.1 Group 1

TS.2

TS.2

TS.1

16
7. Prepare Temporary Support
Calculation of temporary support with staadpro 3D
model.

17
7. Prepare Temporary Support
Load Combination casesinput on staadpro.

18
7. Prepare Temporary
Support
The temporary support maximum
ratio is 0,610 as applied on beam
member no. #8981 and load
combination case no.21

The temporary support

construction is safe for use

19
7. Prepare Temporary SUPPORT TYPE-3
Support
SUPPORT TYPE-1
SUPPORT TYPE-2
• SUPPORT PIPE 114,3x4 (4”)
• BRACING PIPE 76,3x3,2 (2,5”)

SUPPORT TYPE-2

SUPPORT TYPE-1

20
7. Prepare Temporary SUPPORT TYPE-3
Support
SUPPORT TYPE-2
SUPPORT TYPE-2
• SUPPORT PIPE 114,3x4 (4”)
• BRACING PIPE 76,3x3,2 (2,5”)

SUPPORT TYPE-2

SUPPORT TYPE-1

21
7. Prepare Temporary
Support
SUPPORT TYPE-3
SUPPORT TYPE-3

• SUPPORT PIPE 114,3x4 (4”)

• BRACING PIPE 76,3x3,2 (2,5”)

SUPPORT TYPE-2

SUPPORT TYPE-2

SUPPORT TYPE-1

22
 8. Release Temporary
Support Tools & Equipment: Manpower:
# Wrench # Operator Crane
# Crane 25 T # Rigger
# Excavator # Helper

TRUSS

23
8. Release Temporary
The stages of the release
Support
of the support pipe:
• Chainblock and sling
release
• Move counter weight
TRUSS TRUSS

24
8. Release Temporary
The stages of the release
Support
of the support pipe:
• lift the support pipe +-
1 meter from ground
level
TRUSS
• then at the bottom
end pulled using an
excavator

1m
25
8. Release Temporary
The stages of the release
Support
of the support pipe:
• lift the support pipe +-
1 meter from ground
level
TRUSS
• then at the bottom
end pulled using an
excavator

26
8. Release Temporary
The stages of the release
Support
of the support pipe:
• After the pipe support
is released, then it is
installed in a
TRUSS
predetermined area

27
 9. Squences Moving pipe support
1

2
TS 1
3
TS 2
4
• INSTALL TS.1 COLLUMN 1,2,3 &4
5 • INSTALL TS.2 COLLUMN 1,2,3 &4

10

11

28
 9. Squences Moving pipe support
1

2
TS 1
3
TS 2
4
• TS.1 COLLUMN 2 MOVE TO COLUMN 5
5 • TS.2 COLLUMN 2 MOVE TO COLUMN 5

10

11

29
 9. Squences Moving pipe support
1

2
TS 1
3
TS 2
4
• TS.1 COLLUMN 3 MOVE TO COLUMN 6
5 • TS.2 COLLUMN 3 MOVE TO COLUMN 6

10

11

30
 9. Squences Moving pipe support
1

2
TS 1
3
TS 2
4
• TS.1 COLLUMN 4 MOVE TO COLUMN 7
5 • TS.2 COLLUMN 4 MOVE TO COLUMN 7

10

11

31
 9. Squences Moving pipe support
1

2
TS 1
3
TS 2
4
• TS.1 COLLUMN 5 MOVE TO COLUMN 8
5 • TS.2 COLLUMN 5 MOVE TO COLUMN 8

10

11

32
 9. Squences Moving pipe support
1

2
TS 1
3
TS 2
4
• TS.1 COLLUMN 6 MOVE TO COLUMN 9
5 • TS.2 COLLUMN 6 MOVE TO COLUMN 9

10

11

33
 9. Squences Moving pipe support
1

2
TS 1
3
TS 2
4
• TS.1 COLLUMN 7 MOVE TO COLUMN 10
5 • TS.2 COLLUMN 7 MOVE TO COLUMN 10

10

11

34
 9. Squences Moving pipe support
1

2
TS 1
3
TS 2
4
• TS.1 COLLUMN 8 MOVE TO COLUMN 11
5
• TS.2 COLLUMN 8 MOVE TO COLUMN 11

10

11

35
 9. Squences Moving pipe support
1

2
TS 1
3
TS 2
4

• TS.1 COLLUMN 9 MOVE TO COLUMN 12

5
• TS.2 COLLUMN 9 MOVE TO COLUMN 12

10

11

36
10. Set The Equipment Layout
Define crane position to have the optimum lifting plan
Define assembly area position to lift segmen group 2, 3 & 4
Group-2 Group-3 Group-4 Group-3 Group-2

Assembly Assembly
area area
Crane-1 Crane-2

40
 10. Rigging Plan Group-2
ANALISA LIFTING TRUSS 2&3 :

Webbing
Sling
Capasitas
6T

22

41
10 Rigging Plan Group-2
. • Segmen group weight: 6,758 ton • Crane working Radius: 18 meters
• Lifting equipment weight: 1,73 ton • Segmen elevation: 26 meters
• Total weight: 8,488 ton • Boom length: 35,2 meters

42
1. PREPARATION
1.3 MANPOWER PREPARATION
Surveyor
Quality Control
Engineering
Repair team
Material Control
Project Control
Rigger

Site Manager
Supervisor Erector / Fitter
Project Manager
Procurement
Scafolder
Fabrication
Manager 3rd Party Crane Operator

HS
E
8
1. PREPARATION
1.3 MANPOWER PREPARATION
Personil Quantity Grup 1 Grup 2 Grup 3 Grup 4 Grup 5 Grup 6
Erection Erection Assembly Assembly Laydown Repair
Project Manager 1
Site Manager 1
Quality Control 1
Supervisor 2
Safety 2
Surveyor 2
Foreman 6 1 1 1 1 1 1
Erector / fitter 18 4 4 3 3 2 2
Scaffolder 12 3 3 2 2 2
Crane Operator 3 1 1 1
Welder 3 3
Electrical 2 2
Helper 13 2 2 2 2 2 3
TOTAL 66 11 11 8 8 6 13
9
1. PREPARATION
1.3 MANPOWER PREPARATION

10
1. PREPARATION
1.3 LOCATION PREPARATION
Site office

Laydown area
Dumpster
Toilet
Tools warehouse Temporary
utility facility

11
1. PREPARATION
1.4 EQUIPMENT PREPARATION
No. PERALATAN SPESIFIKASI JUMLAH
1 Crawler Crane Cap: 85 ton / Boom: 60m 2 unit
2 Mobile Crane Cap: 35 ton / Boom 32m 1 unit
3 Telescopic Man Basket (Opsional) 4 unit
4 Mobile Crane Cap : 15 ton / Boom 25m 1 unit
5 Truck Cap: 5 ton / Panjang: 12 m 1 unit
6 Light vehicle Pick-up 1 unit
7 Temporary support Pipe / steel profile 20 unit

12
1. PREPARATION
1.4 EQUIPMENT
PREPARATION

• Equipment Layout Plan

• Rigging Plan
• Equipment data sheet
• Engineering lifting chart tabulation
• Surat Izin Layak Operasi (SILO)
• Surat Izin Operasi (SIO)
• Operator license
• Machine inspection report
• Load Test report

13
 • Arrange Crane-1 & 2 capacity 85 tonnes each
1. PREPARATION and divide erection area into 2 areas.

1.4 EQUIPMENT PREPARATION • Put assembly area near erection spot of

cranes.

Assembly Assembly
area area

14
1. PREPARATION Kapasitas Crane 85 Ton pada Boom
42 m radius 24 (kapasitas
1.4 EQUIPMENT PREPARATION efektif 40 Ton)

RIGGING PLAN FOR Cable Sling

(minimal putus 10 Ton)
SEGMENT-1
TRUSS 1 Center of Gravity Segment
Segment weight : 2,16 tonnes
Lifting equipment : 0,24 tonnes
Total Load : 2,4 tonnes

A B
Total calculated
safety factor : C
16,67
OK

15
 Kapasitas Crane 85 Ton pada Boom
1. PREPARATION 53 m radius 16 (kapasitas
efektif 52 Ton)

1.4 EQUIPMENT PREPARATION α

Cable Sling
(minimal putus 10 Ton)
RIGGING PLAN FOR
SEGMENT-2 Center of Gravity Segment

TRUSS 2 & 3 (x2)

Segment
weight : 5,6 tonnes Lifting
equipment : 0,24 tonnes Total
Load : 5,84 tonnes B
A
C
Total calculated
safety factor :
8,9
OK

16
 Kapasitas Crane 85 Ton pada Boom
56 m radius 14 (kapasitas

1. PREPARATION
efektif 55 Ton)

α
1.4 EQUIPMENT PREPARATION
Cable Sling
(minimal putus 10 Ton)

Center of Gravity Segment

TRUSS 4, 5 & 6 (x2)

Segment weight : 5,7 tonnes
Lifting equipment : 0,24 tonnes
Total Load : 5,94 tonnes A B
C

Total calculated
safety factor :
9,26
OK

RIGGING PLAN FOR 17

SEGMENT-3
1. PREPARATION
1.4 EQUIPMENT PREPARATION α Kapasitas Crane 85 Ton pada Boom
61 m radius 22 (kapasitas
Cable Sling efektif 14 Ton)
(minimal putus 10 Ton) Center of Gravity Segment

TRUSS 7 (x2)
Segment weight : 2,25 tonnes
Lifting equipment : 0,24 tonnes
Total Load : 2,49 tonnes
A B
C

Total calculated
safety factor :
5,62
OK RIGGING PLAN FOR
SEGMENT-4

18
1. PREPARATION
1.4 EQUIPMENT
PREPARATION

19
1. PREPARATION
1.5 TOOLS PREPARATION
No. PERALATAN SPESIFIKASI JUMLAH
1 Sling Dia. 1/2” 800 m
2 Chain Block Cap: 5 ton 28 unit
3 Counter weight Concrete box 32 unit
4 Turn buckle M16 60 set
5 Scafolding Pipa 1-1/2” – 6m To be calc.
6 Welding Machine TBN 2 unit
7 Cutting Torch TBN 2 unit
8 Kunci Momen TBN 2 set
9 Light Tools TBN 1 Lot
10 Consumable TBN 1 Lot

20
1. PREPARATION
1.5 TOOLS PREPARATION
No. PERALATAN SPESIFIKASI JUMLAH
11 Measurement TBN 5 pcs
12 Lighting set TBN 2 set
13 Handy Talkie TBN 5 set
14 Total station TBN 1 set

21
1. PREPARATION
1.5 TOOLS PREPARATION

22
1. PREPARATION
1.6 SAFETY PREPARATION

• Job Safety Analysis

• Hazzard Identification Risk Assessment and
Determining Control
• Personal Protective Equipment
• Safety sign
• Tools box meeting
• Safety report

23
1. PREPARATION
1.6 SAFETY PREPARATION
SUPPORT TYPE-3

SUPPORT TYPE-2

SUPPORT TYPE-2

Ladder Acces SUPPORT

24 TYPE-1

Manpower
Erection 20
1. PREPARATION
1.6 SAFETY PREPARATION

24
1. PREPARATION
1.6 SAFETY PREPARATION
Angkur dengan Sling
Weebing/rope/wire
Safeline
Tali sling 10mm
Connector rabiner

Pergerakan Connector /rabiner/

menggunakan Safeline hook
Horisontal

Double Lanyard/ tali

pengaman tubuh
24
Platform Work
• Platform work shall be
installed on each spot of
worker tightening area.
1. PREPARATION
1.7 MATERIAL PREPARATION
• Prepare material support
• Prepare crane and rigger on laydown area
• Prepare quality control and material control
on laydown area
• Prepare Rigging Plan for un-loading
• Quantity and quality check on first receiving
and prepare Material Receiving Report
• Arrange material on laydown area with
First-in-First-out system

26
2. ERECTION METHOD
2.1 ERECTION DOCUMENT

• Erection documents to be prepared during erection:

• Engineering erection drawing
• Inspection and Test Plan
• Method erection
• Inspection report of concrete foundation
• Coordinate and centreline of foundation
• Verticality and plumbness plan

27
2. ERECTION METHOD

2.2 ANCHOR
INSTALLATION
• First method is installation of
Anchor Bolt as per engineering
design.

28
2. ERECTION METHOD
2.3 CIVIL WORK TRANSFER REPORT
• Receiving civil work transfer
report document after pouring
concrete
• work is done
Join inspection between civil
• contractor, consultant, and owner
Check list of inspection:
• Foundation dimension check
• Foundaton elevation check
• Foundaton

MAR 29
2. ERECTION METHOD
2.3 SET PADDING PLATE Padding Plate

Elevasi
Baseplate

Grouting

• Set baseplate elevation using padding plate

• Number of padding plate based on baseplate dimension and load
• Padding plate set using sika grout

30
2. ERECTION METHOD
2.4 FIRST TRUSS SEGMENT INSTALLATION

Sca Folding
Truss-13

• Erect Truss-1 and 13 for all grid with

crane
• and scaffolding.
Truss-1 and 13 erected complete with gordyn,
• M-Truss and purlyn.

Sca Folding Erection shall comply standard quality and

safety
31
2. ERECTION METHOD
2.4 GROUND ASSEMBLY
• Prepare assembly area as near as possible
with the location of erection.
• Assembly segmen 1, 2, 3, and 4 as per
engineering divide weight and size.

32
2. ERECTION METHOD
2.5 TEMPORARY SUPPORT ERECTION
• Erect temporary support as per
engineering design.
• Temporary support position shall
consider connection distance of each
segment and consider center of gravity
on all column assembly.
• Temporary support shall supported by
sling and counterweight.
• Each temporary support erection shall
inspected by quality control division and
safety department before its being
erected.

33
2. ERECTION METHOD
2.6 COLUMN ERECTION
3 2 • Erect Coal Shed member with sequence as
follow:
1 1. Truss-2-3 and 11-12 simultanousely
with two Crane.
2 2. Truss-4-5-6 and 8-9-10 simultanousely
with Two Crane.
3.
1
Truss-7 only with single Crane.
4.
Over length deviation on Truss-7
erection should be avoid and repeat
the previous segment.
5.
Less length deviation on Truss-7 could
be tolerance less than 0,5 meters and
shall apply to other column for
• Eachuniformity.
segment elevation shall checked by
surveyor and inputted by quality control on
verticality form check during erection.

34
2. ERECTION METHOD
2.7 CONTINOUS ERECTION
• Repeat the method into latest grid
• After 2 column erected properly grouting
shall be proceed.
• After 4 column erected properly
temporary support could be released.

35
3. REPAIR PROCEDURE
3.1 CONTENT

• Codes and Standard

• Inspection Procedure
• General repair procedure

36
3. REPAIR PROCEDURE
3.2 CODES AND STANDARD

• Kode AWS D1.1: Kode Pengelasan Struktural - Carbon Stell

• Pedoman Kesehatan dan Keselamatan Kerja SNI

37
3. REPAIR PROCEDURE
3.3 INSPECTION PROCEDURE
• Classiffied damage material into two categories:
• Able to repair based on repair tools on site
• Reject and shall replace
• Marked by quality control
• Marked on material inspection defect list
• Define types of repair:
• Welded
• Fitted
• Fabricated
• Modified
• Inform to client, consultant, or owner
• Repair the material
• Report for closing

38
3. REPAIR PROCEDURE
3.3 INSPECTION PROCEDURE

Able to be repaired Rejected

39
3. REPAIR PROCEDURE
3.4 GENERAL REPAIR PROCEDURE

1. Clean the welded surface area with brushing up to 5 mm from each side of
the area to be welded.
2. The area to be re-welded shall be ground to a depth of at least 2 mm.
3. The surface to be welded and the surface adjacent to the weld must be
dry and free from scale, slag, rust, moisture, oil, and other foreign
materials that prevent proper welding.
4. Perform a Dye Penetrant test to all areas that need to be welded. Carry
5. out the welding process according to the approved WPS / PQR.
6. Remove all welding slag, spatters and make sure the surface is clean
for
plating. 40