Al-MUHAYLIB Group Co.

Cement Production

METHOD STATEMENT FOR THE CONSTRUCTION OF BATCHING

PLANT

CHECKED : PREPARED BY REVIEWED BY APPROVED BY

 Al-MUHAYLIB Group Co. Cement Production

METHOD STATEMENT FOR THE CONSTRUCTION OF

BATCHING PLANT

PROJECT : NEOM LINE

CLIENT : NEOM

CONTRACTOR : AL-MUHAYLIB GROUP COMPANY FOR CEMENT

PRODUCT
 Al-MUHAYLIB Group Co. Cement Production

TABLE OF CONTENTS
SECTION CONTENT PAGE

1 SCOPE OF WORK

2 MOBILIZATION

3 PROPER PASSAGE FOR THE WORKERS & STAFF

4 MATERIAL REQUIREMENTS

5 HEALTH & SAFETY

6 EMERGENCY EVACUTION PROCEDURE

7 RESPONSIBILTIES

8 PROCEDURE TO CARRY OUT ERRECTION FOR BATCHING

PLANT

9 FINAL INSPECTION

10 MANPOWER REQUIREMENT

11 PLANT & EQUIPMENT REQUIREMENT

12 PLANT INSTALLATION
 Al-MUHAYLIB Group Co. Cement Production

1.0 SCOPE OF WORK

The purpose of this method statement is to outline the general requirements which should
be taken into consideration for the construction of the batching plant. This document
defines the methodology, sequence, control measures, safety requirements for office Porta
Cabins & Equipment Mobilization, General loading, unloading and lifting operation of
construction materials / equipment’s.

2.0 MOBILIZATION

2.1) SCOPE:

The scope of work described in this statement is applicable for site mobilization
works for all works.

The requirements and procedures in mobilization of office container & equipment.

Lifting plan.

Lifting sequence.

Site Location.

DRWAING

Safety & Environment precautions.

Proposed location for Client office, Engineering office, Site laboratory, Warehouse, Workshop.
Plumbing Layout Diagram Activity Hazard Analysis

3.0 MEANS OF EGRESS=PROPER PASSAGE FOR THE STAFF & WORKERS

DEFINITION FOR MEANS OF EGRESS

 Al-MUHAYLIB Group Co. Cement Production

It is a continuous and unobstructed way of exit travel from any point in a building or
structure to a public way, and consists of three separate and distinct parts:
1- The way of Exit access, Is that portion of a means of egress which leads to an
entrance to an exit
2- The Exit, Is that portion of a means of egress which is separated from all other
spaces of the building or structure by construction or equipment to provide a
protected way of travel to the exit discharge
3- The Exit discharge, Is that portion of a means of egress between the termination of
an exit and a public way. Must lead directly outside or to a street, walkway, refuge
area, public way, or open space with access to the outside . . .(This area) must be large
enough . . .

4.0 MATERIAL REQUIREMENTS

 CHANNELS
 H-BEAMS
 ANGLE BARS
 BOLTS AND NUTS
 STEEL PIPES
 STEEL PLATES AND CHEQUERED PLATES
 STEEL REINFORCEMENTS
 CONCRETE
 OXY-ACETLYNE TANK
 ELECTRICAL WIRES & CABLES, TIES AND CONDUITS, ELECTRIC TAPES
 CIRCUIT BREAKER AND PANEL BOARDS

5.0 HEALTH AND SAFETY

 DAY SHIFT
- Inspection of plants and equipment’s
- Provision of welfare facilities like toilets, water, shaded Area, Smoking Area to be
provided
 NIGHT SHIFT
- Proper Ventilation
- Proper lights
 Al-MUHAYLIB Group Co. Cement Production

- Welfare Facilities
- Emergency Signs to be Installed

6.) EMERGENCY EVACUATION PROCEDURE

6.1) EMERGENCY ALARM / SIREN SOUND

6.2) STOP ALL WORKS / ACTIVITIES

6.3) SHUT OFF ALL EQUIPMENTS

6.4) ALL PERSONNEL PROCEED TO NEAREST

ASSEMBLY POINTS IN ORDERLY MANNER. CHECK FOR WIND DIRECTION

6.5) CONDUCT HEAD COUNT (BY SUPERVISORS) AND REPORT MISSING PERSONNEL

6.6) WAIT FOR “ALL CLEAR” INSTRUCTION

7.) RESPONSIBILITIES

7.1) FACTORY MANAGER

- Responsible to support whatever the erection team require to complete the

dismantling and erection of the batch plant as schedule in safely manner.

7.2) ERECTION SUPERVISOR

- Fully responsible to supervise the dismantling and erection of the batch plant
by following the procedure and to make sure the safety of his team to finish the
work on safe and to meet the schedule.

7.3) HEALTH AND SAFETY OFFICERS

- To monitor the daily activities of the erection team and ensure all work done
according to safety policy

- Conduct weekly toolbox meeting

- Ask to conduct daily housekeeping to avoid from, slip, trip and fall hazards.
 Al-MUHAYLIB Group Co. Cement Production

- Conduct visual inspection for the equipments

8.0) PROCEDURE TO CARRY OUT ERECTION OF BATCH PLANTS

I- METHOD OF BP ERECTION

STEPS DURATION WORK DESCRIPTION EQUIPMENT

Batch Plant: 1-100 ton

and1-090 ton
1 12 hours Fixing of column H-beam supports on the foundation.
crane
2 (1st day) Erecting batch plant main body, fully bolted.

3 Placing aggregate bin extension, fully bolted

4 Erecting radial feed conveyor.

5 Placing aggregate bin cover, fully bolted.

6 12 hours Fixing of steel beam supports for central drum mixer 2 units-50 ton
crane
7 (2nd day) Erecting central drum mixer.

8 Placing of ground hopper, fully bolted.

9 Placing of batch control cabin.

10 Fixing steel supports of vertical cement silo.

11 Erecting vertical cement silo, fully bolted.

12 120 hours Electro-mechanical works, computerization, and

(2nd to 10th Waterline piping installation.

day)
 Al-MUHAYLIB Group Co. Cement Production

II- TANDEM METHOD ERECTION OF BP MAIN FRAME:

ITEM LOAD LIFTING DATA WORK

DESCRIPTION SPECIFICATION
NO

1 Lifting of batch TWO UNITS CRANE 1. Certified

plant main crane
1 unit-100 1 unit-090
frame including
ton crane: ton crane all lift
(Weight:35 ton)
accessorie
Main Boom : 22.3m. 19.6m s.
Radius : 7.0m. 7.0m
2. Certified
Capacity : 43.6 ton 41.0
crane
ton
operator
Load Share : 17.5 ton 17.5 and
ton rigger.

Lift Accessories: 2.0 ton 1.5

ton 3. Lift Plan

Total Lift Weight: 19.5 ton 19.0

ton

Safety : 44.7% 42.6%

Lifting of TWO UNITS CRANE

vertical cement
1 unit- 100 1 unit-090
silo
ton crane: ton crane:
(Weight: 12
ton)
 Al-MUHAYLIB Group Co. Cement Production

Main Boom : 22.3m. 19.6m.

Radius : 7.0m. 10.0m.

Capacity : 43.6ton 25.3ton

Load Share : 12.0ton 6.0ton

Lift Accessories : 1.3ton

1.0ton

Total Lift Weight: 13.3ton

7.0ton

Safety : 30.5% 27.6%

9.) FINAL INSPECTION

9.1) to be carried out by operation and informed Al Rajhi for schedule of Final Inspection

10.) MANPOWER REQUIREMENT:

10.1) STAFF

NO. STAFF Numbers

1 Factory Manager 1
2 Project Engineer 1
3 Supervisor 1
10.2) ERECTION/DISMANTLING TEAM
4 QA/QC Engineer 1
5
NO. HSE MANAGER
DESCRIPTION 1
NUMBERS
1 Erection/project in charge 1
2 Civil Engineer 1
3 Welder 4
4 Electrician 3
5 Crane Operator 1
6 Civil construction crew 15
7 Helper 4
8 Man lift operator 1
 Al-MUHAYLIB Group Co. Cement Production

11.0) PLANT AND EQUIPMENT REQUIREMENTS

11.1) EQUIPMENT TO BE USED

* Mobile Cranes

* Bucket boom trucks

* Trailer trucks

* Generator Set

* Welding Machine

* Mixer Truck for pouring silo foundation

* Masonry trowels and other hand and power tool

* Risk Assessment

12.0) PLANT INSTALLATION

12.1) Construction of the batching plant foundation

The installation of the concrete batch plant is an assembly line, so each part must be positioned at
the foundation in line with the drawing requirements and the construction work should cooperate with
each other in the installation process. However, the engineering geological conditions are various in
different places, so the foundation structure of the concrete batching plants are different too.
Camelway engineer and technical staff will customize the specific installation scheme according to
customers’ demand.

12.2) The installation of the concrete mixer

The installation of the concrete mixer should be in strict accordance with the work conditions of the
mixer in the installation process so as to reduce later alteration. We should pay attention to the
following points during the installation process of the equipment.

The installation site should be leveled with a solid foundation and the pit in the ground should be slightly
above the ground to prevent the water flowing into the pit. In addition, the bearing capability of the
 Al-MUHAYLIB Group Co. Cement Production

foundation should reach the required demand to avoid the influence on equipment operation caused by
late sedimentation.

Use cranes to hoist the mixer hoist. The four legs, cross bracing, diagonal bracing, ladders, and up and
down tracks of the main structure should be installed aligning with the pits. The equipment should be
positioned in the same horizontal plane and the track frame shall not be twisted and misaligned.

You also should consider whether the ancillary projects like power, water, rainproof measures and
transport corridors of the materials sites meet the mix requirements. The supporting legs and the
embedded part should be welded firmly and there should be no impurity in the welding seam.

The supporting legs must be vertical to support the mixer weight. The diagonal bracing must be firmly
welded and fastened with the supporting legs to ensure the mixer's integrity.

12.3) The installation of cement silo

The crane is used to hoist the cement silo vertically and move it to the foot of the cement silo
foundation. There are steel plate embedded parts at the foundation of the cement silo. Before hoisting
the cement silo, you should do the flatness measurement of the horizontal plane to ensure the four
supporting legs in one same horizontal plane. After the cement silo is in place, the crane is gradually
loosened until it reaches the flat surface of the embedded part. The four legs are respectively spot-
welded by spot welding method to prevent the swinging of the cement silo. Then using the vertical ball
to check the verticality, and the undesired parts should be partially padded until all legs are vertical.
Then, the full position of the four legs should be fully welded without any impurity in the welding seam
during the welding process. The lifting hook can not be loose before the welding process is finished. The
process of loosening should be carried out slowly. The construction workers should be evacuated to the
extent of 10 meters. The wire rope should be slightly loosened again and wait for observation. The
personnel of the survey team should monitor it. Ten minutes later, if no change is found, remove the
crane hook to complete the installation of cement silo. After the cement silo installation is finished, the
same method should be used to install the fly ash silo and make monitoring.

12.4) The installation of the screw conveyor

The entrance part of the screw conveyor should be near the end of the motor, the exit near the other
end. Use crane to lift the conveyor to the entrance and exit position with a as small as possible
installation angle to determine the distance of the conveyor from the exit and entrance positions. The
exit position of the screw conveyor should be as close to the end face. Then fix the conveyor
 Al-MUHAYLIB Group Co. Cement Production

preliminarily and according to the import and export position try to keep the interface tube in a vertical
position. After the interface tube is welded, and then fixed conveyor finally.

12.5) The installation of electric and other circuits

The electric and other circuits mainly consist of various signals control lines, power circuits, pneumatic
control lines, waterways, etc. They should be installed respectively in accordance with the number of
dismantling before doing the installation. During the installation process, you should pay attention to
the marks that should correspond one to one, if the mark falls off, you should firstly install the circuit
with the mark so as to the positions of the circuit without mark can be determined. The installation of
concrete batch plants is a complicated work and it needs a professional operation team that can ensure
both the security and efficiency. Camelway can provide the equipment installation service according to
customers' practical requirements.
Al-MUHAYLIB Group Co. Cement Production