METHOD STATEMENT

FOR
METHOD STATEMENT FOR FABRICATION OF STEEL GIRDERS

CLIENT/EMPLOYER
MUMBAI METROPOLITAN REGION DEVELOPMENT AUTHORITY

GENERAL CONSULTANT/ENGINEER
SYSTRA-CEG-SMCIPL CONSORTIUM

CONTRACTOR
J. KUMAR INFRAPROJECTS LTD.
Project: MMRDA/09/MMRP/CA48: DESIGN AND CONSTRUCTION OF ELEVATED VIADUCT AND NINE
(9) ELEVATED STATIONS (EXCLUDING ARCHITECTURAL FINISHES AND PEB ROOF STRUCTURE)
INCLUDING TWO (2) FLYOVERS, AND UNDERGROUND TWIN TUNNEL, CUT AND COVER, RAMP AND
ONE (1) UNDERGROUND STATION (INCLUDING ARCHITECTURAL FINISHES AND PEB STRUCTURES) FOR
CORRIDOR OF MUMBAI METRO LINE 9 i.e. EXTENSION OF LINE 7 FROM DAHISAR (EAST) TO MIRA
BHAYANDAR AND ANDHERI TO CSIA OF MUMBAI METRO RAIL PROJECT OF MMRDA.

DOCUMENT CONTROL No: JKIL/MMRDA/LINE09/79 Revision - R0

Name Department Signature Date

Prepared By Mr Sachin Chaugule Planning Engineer

Reviewed by Mr. B. S. Rawat QA/QC Incharge
Reviewed by Mr. Ashish Mishra SHE Manager
Approved By Mr. Subrata Adhikary Project Manager

Designation Name Signature

Chief Quality Mr. Venkata Satyanarayana

Reviewed By
assurance Expert Lakkavajjala
Reviewed by Chief Safety Expert Mr. Bhamidipati Seshu Babu
Reviewed by Erection Incharge Mr. G. S. Mallapa
Deputy Project
Reviewed by Mr Niteen Raosaheb Deshmuk
Director
Approved By Project Director Mr Apostolos Folas

INDEX
 METHOD STATEMENT FOR FABRICATION
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Doc. No: JKIL/MMRDA/LINE09/79- (R0)

Contents
1. PURPOSE:...............................................................................................................................................3
2. REFERENCE:...........................................................................................................................................3
3. RESPONSIBILITIES..................................................................................................................................3
4. ORGANIZATION CHART..........................................................................................................................5
5. LIST OF EQUIPMENT..............................................................................................................................5
6. SEQUENCE OF WORK:-...........................................................................................................................6
7. MANDATORY SAFETY REQUIREMENTS................................................................................................18
8. ENCLOSURES........................................................................................................................................20

1. PURPOSE:
The objective of this method statement is to fabricate the steel girder as per IS
specifications. Work formulate as a summary of all quality related activities required to

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meet the terms of the contract as per the approved drawings & relevant technical
specifications.

2. REFERENCE:
 Contract Specifications
 IRS: Concrete Bridge Codes
 Project SHE Plan
 SHE conditions of contract
 Approved Project Quality Management plan
 Steel grade conforming to IS: 2062-2011

3. RESPONSIBILITIES
Following are the responsibilities and reporting structure of personnel involved in the scope of the
procedure:

Position Reporting / Responsibilities

Project Manager
Deputy Project Manager
Surveyor
QA/QC In charge
Chief SHE Manager
Shall report to management,
Shall report to the Project Manager
Shall be responsible for control, supervision and direction for
implementation and execution of construction plans.
Shall also be responsible for supervision of construction activities and
preparation of records, procedures and prepare progress and
completion reports
Reporting to the Deputy Project Manager.
Interacting with the shifting in charges about the daily activities.
Up keeping the survey instruments including calibration in consultation
with QC/QA section and safe custody.
Documentation /protection of benchmark and survey points.
Interacting with Engineer’s survey department representatives.
Responsible for reduced level of each and every erection related work.
Ensuring line leveled as per survey records.
Shall report to Project Manager.
Shall be responsible for overall control of QC activities and sub-
contractor’s QC activities as per approved ITP and implementation of
Project Quality Plan.
Shall be responsible for carrying out Inspection as per specification.
Reports to Project Manager

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Position
Plant In-charge
Sr. SHE electrical Engineer
Sr. SHE Manager
Sr. SHE Traffic Engineer
Sr. SHE Fire Manager
Male Nurse/ First Aider
 Shall ensure the availability Ambulance and First aid box at work site.
Riggers
Labour Welfare Officer
Reporting / Responsibilities
Co-ordinates with corridor in charge for system implementation
Closely monitors all the pre-requisites for EHS
Involves in hazard identification, risk assessment and its control
measures.
Organize training programs on safety awareness.
Implement and supervise EHS requirements before commencement
and during work.
Ensure periodic preventive maintenance of all major machines &
equipment's at site
Timely breakdown repairs of all machinery & electrical equipment's as
per their inspection manual
Monitoring of efficiency of all major equipment for site activity
Internal & Third party testing of machines & equipment prior to their
due date of testing
Calibration of all machines & equipment deployed at site.
Shall report to Chief SHE Manager
Shall be responsible for monitoring and implementation of Electrical
norms and arrangements
Shall report to Chief SHE Manager
Shall responsible for monitoring and implementation of SHE norms and
policies at work place.
Reports to Chief SHE Manager
Prepare Traffic diversion plans
Verification of diversion boards & Caution boards
Allocation of Traffic marshals
Shall report to Chief SHE Manager
Shall be responsible for monitoring and implementation of fire norms
as per approved manual.
Shall report to Chief SHE Manager.
The first aider is to provide immediate, temporary care to someone
who is ill or injured.
Shall report to Plant in-charge.
A rigger is responsible for fastening heavy loads to transportation
equipment and controlling, supervising and directing the equipment's
operators.
Shall report to Project Manager
Shall be responsible for facilities of labour activities.
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Position Reporting / Responsibilities

Maintaining of data of labour
Shall report to Launching Manager & SHE Manager
Emergency Response Evaluate the Severity, Potential Impact, Safety Concerns, and Response
team Requirements
Communicate and provide incident briefings

4. ORGANIZATION CHART

Project Manager

Head QC Cheif SHE Surveyor Section Erection Vendor

QA/QC Engineer Manager Incharge Incharge Incharge

Site
Safety
Engineer
Officer

Supervisior

5. LIST OF EQUIPMENT

Sr.
Description Quantity (In Nos) Remarks
No
1 Plasma Cutting Machine 2

2 Welding Machine 1

3 Drilling Machine 2

4 Paint Pump 2

5 Hydra 15 / 20 Ton 2 + 1*
6 Gantry 15/ 20/ 25 Ton 2 + 1*

7 Air Compressor 4 + 2*
8 Cutting Set 2 + 2*
9 Grinding Machine 10

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Sr.
Description Quantity (In Nos) Remarks
No
10 Stud Welding Machine 1

6. SEQUENCE OF WORK:-
 Drawing Approval
 Submission of QAP
 Raw Material Procurement
 Material Testing
 Material Cutting
 Bevelling the edges of the web
 Fitting if Web & Flange
 Arc Welding
 Fitting of Gusset Plate & Stiffners
 Testing
 Cleaning of Drilling Holes
 Shot Blasting / Metalizing & Painting
 Stud Welding
6.1. Drawing approvals
1) Final and approved (signed and stamped by client) GAD will be required to start
the process.
2) Shop/ fabrication drawing will be prepared based on above GAD and will be sent
to client for approval.
3) Once the fabrication drawings are approved by the client, these drawings will be
issued for fabrication to the shop floor.

4)
5)
6.2. Submission of QAP:
i) To ensure the proper Quality of fabrication Quality Assurance Plan (QAP) is prepared.
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ii) The QAP shall be consisting of following aspects.

a) Brief Details of Project
b) Contract Agreement No.
c) Loading Standard
d) Governing Specifications:
e) Drawing References:

6.3. Raw Material Procurement:

A fabricator's work starts from the point of procurement of raw materials including
fasteners and ends with the dispatch of the fabricated items to site for erection. In order
to ensure that the fabrication can be carried out in accordance with the drawings, it is
necessary that inspection and checking is carried out in accordance with an agreed
Quality Assurance Plan
(QAP). The plan should elaborate on checks and inspections of the raw materials and
also of the components as they are fabricated, joined etc.

6.4. Material & Raw Material Testing:

i) About Raw Material:

Steel grade conforming to IS: 2062-2011 (with latest amendment), is proposed to be used for all
components for all spans as per approved drawings.

The steel shall comply in all respects with the requirements of approved drawings and relevant
codes and specifications and shall be procured from approved manufacturers only. It may be
noted that quality of steel used for fabrication shall be the essence of the contract & shall be
rigidly followed. Steel sections to be supplied by the manufacturers shall be ultrasonically tested
as per provisions at the manufacturer’s premises before dispatch. The Contractor on receipt of
supply in his factory premises/fabrication workshop shall carryout random USFD testing as per
standards laid down in various codes and verify them with the list received from manufacturers.
Only tested steel shall be used for fabrication.

Steel should be procured only from SAIL, RINL, TISCO or JINDAL such reputed steel
manufacturers only.

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(ii) Raw Material Testing:

From this Raw Material, a small cut-bits has to be sent to Certified Testing Laboratory or
government testing agencies for testing the properties of the metal. After testing the metal in
the Laboratory, they will give a clearance test certificate for the material for the Starting of
fabrication for the composite girders.

6.5. Raw Material Cutting:

For the Cutting of Raw Material, We have a wide range of Two MESSER CNC Plasma Cutting
machines that is manufactured from the best quality components ensuring safety, high
performance and long durability. This machine can be made cutting in different sizes and
specifications. (For ex:- webs, flanges, splice plates, gusset plates, web stiffeners, bearing plates).
High speed & precision, strongly anti-interference, different model & application we also meet
Customized Requirement for our clients benefit. It specially applied for CNC
plasma/flame/water jet cutting machine. The system is equipped with a nine-tool carousel
with auto tool changer, and can have as many as four cutting torches -- although two are
normally sufficient. Marking can be done by inkjet, plasma, powder or punch. Fabricator’s
performance is enhanced by Farley patented plate clamping system, which minimizes chatter
and plate movement, the drill life has been up to 40-60% longer than on a large heavy duty
machining centre with conventional edge clamping.

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We can eliminate over 90% of handling in parts to be drilled and profiled. High speed drilling
available with efficient plasma cutting offers improvements in output of +300%. Multi set-ups
materials are savings through better nesting on big plates. It can typically improve productivity
by three to five times, while introducing better accuracy, more flexibility and greater range. All
these aspects add up to lower cost parts.

6.6. Bevelling the Edges of the Web:

Before making the I-beam fit up, the two sides of Web edges must be bevelled (in lengthwise of
web) with grinding machine in top and bottom of web edges For the Deep penetration of the for
Double Bevelled Butt welding.

6.7. I -Beam fit up of Girder:

After bevelling the web edges, the flanges and webs will be assembled in I-beam Shape. These
Composite girder I-beam will be fitted on platform or bay for Correctness and perfection in the
girder. While making the Fit-up Tack Weld is make With the Arc Welding.

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6.8. Sub Merged Arc Welding (SAW):

After Making the I-beam fit up of Girder, Submerged Arc Welding Will done for the Girder. In
SAW (Submerged Arc Welding) an arc is struck between the work piece and the end of a
consumable electrode, both of which are covered by a layer of granular flux (hence ‘submerged’
arc). The arc is therefore hidden. Some of the flux melts to provide a protective slag cover over
the weld pool. The remainder is collected for re-use.

The Double layer run welding will be done on four positions of the girder. First layer i.e. root
layer will be done. And the second layer will be done on the root layer. As per the Standards the
depth of the Weld fillet must be = Thickness of web plate * 0.78.

6.9. Assembly of I-Beam Girders and Fit up of Web Stiffeners and Gusset plates:

After completing the Sub-merged arc welding the I-Beam Girders are assembled in platform and
after confirming the required camber will fit up the web stiffeners, Gusset Plates and at the same
time Splice Plates will be marked for Drilling.

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Note: Tolerances and limits in all levels are fallowed by as per RDSO standards.

6.10. MIG Welding for the fitted Stiffeners, Gusset plates and others:
After Making the Fit up of Web stiffeners and gusset plates, MIG welding will be done for
Stiffeners and gusset plates

6.11. Conducting of DP test For the Sub-merged Arc Welding:

After Completion of Submerged Arc Welding, Our QC Engineers Will Conduct the DP test for the
SAW Weld joint of Girder. Dye Penetrated PM-10, Developer PM - 24 and Cleaner PM - 30 are
used for Non Destructive Testing, for the process of Crack detection in Weld Joints.

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Sequence of Dye Penetrate Testing Process:

• Completely clean the test area by spray of Cleaner PM 30 wiping with a

cloth Soaked in Cleaner PM 30. Remove oil, grease, dirt & dust from test area.
• Apply Red Dye Penetrated PM - 10 by Spray or Brush. Allow to stand for
dwell Period (penetration time of 10 to 15 minutes) for the dye to penetrate in
cracks.
• Clean excess Dye from the test area by wiping with a cloth soaked in Cleaner.
• Spray Developer PM-24, uniformly, from a distance of 6 -8 inches from test area.
• Do not spray too close /over-spray. This may give wrong results.
• Observe the Test Area for development of red marks on cracks / surface defects.

6.12. UT TEST FOR THE WELDING PROCEDURE:

Ultrasonic Testing (UT) uses high frequency sound energy to conduct examinations and make
measurements. Ultrasonic inspection can be used for flaw detection/evaluation, dimensional
measurements, material characterization, and more. To illustrate the general inspection
principle, a typical pulse/echo inspection configuration as illustrated below will be used.

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Ultrasonic Inspection is a very useful and versatile NDT method. Some of the advantages of ultrasonic
inspection that are often cited include:

• It is sensitive to both surface and subsurface discontinuities.

• The depth of penetration for flaw detection or measurement is superior to other
NDT methods.
• Only single-sided access is needed when the pulse-echo technique is used.
• It is highly accurate in determining reflector position and estimating size and
shape.
• Minimal part preparation is required.
• Electronic equipment provides instantaneous results.
• Detailed images can be produced with automated systems.
• It has other uses, such as thickness measurement, in addition to flaw detection.

6.13. Cleaning & Drilling Holes:

After MIG welding, the Next Process is cleaning of the girder. At this stage we will remove that
metal patches by using Chipping Rods and grinding machines. And also drilling of holes is to be
done on the Web, Flange & Splice Plates of the girder by using Broach cutter Drilling Machine.

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6.14. Shot Blasting, Metalizing and Painting:

a) Surface Preparation by Shot Blasting :
1. Blasting is the process where small angular or spherical particles are propelled at a part
by compressed air, or mechanical high speed rotating wheels or water pumps.

2. We are using shot blasting for the girders and other structure, which is advanced
compare to sand blasting.

Grits (Tiny Steel Grits)

Shot Blasting Booth

b) Metallizing with Aluminum Wire :

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1. The Aluminum metal spraying should be carried out as soon as possible after the surface
preparation by shot blasting and in any case with in such period that the surface still
clean and without any visible oxidation. If deterioration, in the surface to be coated is
observed by comparison with strictly proposed stock surface, similar quantity
preparation treatment by shot blasting is repeated before the Aluminum spray is
applied.

2. Minimum thickness of metal coating applied shall be 115 microns and average thickness
shall be 150 microns. The metal coating shall be checked for thickness by approved
magnetic thickness measuring gauge. At least one reading for each sqm of area painted
shall be taken. The calibration of the gauge shall be checked against a standard of similar
thickness within an accuracy of 10%.

c) Painting :
Specification for Painting:
1. We maintain the paints and oils shall conform to IS specifications and shall be from
RDSO’s approved list of manufactures.

2. The paints used for the work shall confirm to the following specifications and the sample
should be tested at government authorized or NABL Laboratories.

a) Etch Primer – IS specification 5666.

b) Zinc chrome primer to IS specification 104 of 1962.
c) Paint Aluminium to IS specification 2339-63.

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2. One coat of wash Etch primer to IS: 5666 shall be applied first. After 4 to 6 hours or the
application of the wash primer, one coat of Zinc chrome primer to IS: 104 with the
additional provision that Zinc Chromate shall be applied.
3. The third coat shall be by Aluminium paint conforming to IS: 2339. The girder parts shall
be dispatched to site after the third coat (i.e. first finishing coat or cover coat.
4. After assembling and launching at site, second finishing coat of Aluminium paint
conforming to IS: 2339 shall be applied after touching up the primer and first finishing
coat.

6.15. Stud Welding for the Girders:

Electrical arc stud welding involves the same electrical, mechanical, and metallurgical principles
found in any other arc welding process. Nelson Stud Welding manufactures a vast range of studs
in Drawn Arc, Short Cycle and Capacitor Discharge as well as many special types for specific
industries.

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In the stud welding process, the power source and the stud welding control system are set
control the amperage and the arc duration or time. The welding gun has the trigger activated circuit
to initiate the weld and a lifting mechanism to draw the stud away from the base material and
initiate the welding arc. The gun includes a stud holding chuck, two legs, a foot piece and a ferrule
grip to hold the ceramic ferrule (also called as an arc shield).

Sequence of Stud Welding Operations:

i) Stud and Ferrule are loaded into the Gun and properly positioned against the Base Plate.
ii) The Gun is pushed against base material taking up the plunge or stud length available for
burn off against the gun spring pressure. The trigger button is depressed to start the fully
controlled automatic sequence. This sequence consists of initiating the weld current, and
lifting the stud to create an arc by energizing the gun solenoid.
iii) The arc duration time is completed and the stud plunged into the molten pool by means of a
spring when the gun solenoid is de-energized and turning off the weld current at the time of

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weld cycle.
iv) The weld is completed and the gun is lifted off the stud and the ceramic ferrule removed.
The stud is inspected for weld Quality.

7. MANDATORY SAFETY REQUIREMENTS

Occupational Health & Safety control measures shall be strictly followed during transportation &
erection of Precast Elements as per Project Safety, Health & Environment Plan. Hazard Identification,
Risk assessment and Risk control measures associated with the operation have been identified and
necessary action plan has been initiated as per procedure before start of the work. Safety Checklists
has also been developed for monitoring the implementation of control measures before and during
execution of work. The general safety operational control measures to be ensured are as below.
 Tool Box meeting to be conducted before starting the work. All the workmen will follow the
safety rules as per the contract.
 Work Permit System shall be followed for the medium and high risk activities as per laid down
procedure.
 Safety Harness while working at height
 The work area shall be properly barricaded as laid down in the lift/construction depot plan.
Access Control shall be exercised to check the un-authorized person within construction area.
 Ambulance with First aid box & fire extinguishers shall be kept at site.
 Caution boards indicating danger will be fixed at proper place.
 Safe access should be provided and should covered with green net.
 During night proper illumination shall be done for lighting up the area.
 All the workers and supervisory staff’s shall wear PPEs during the execution.

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 The work methodology of the activity will be explained to all the key personnel and workmen
involved in that activity and standing instructions will be given.
 TBT or Training shall be provided before starting the work.
 Emergency contact numbers should be displayed.
 Operator, Workmen and Foreman shall have adequate knowledge and experience.
 Lifting Devices (Cranes & Tackles etc.) shall be inspected before operations to ensure safe
working condition.
 Daily inspection checklist to be completed by site engineers and safety personnel before
starting the work.
 Responsible Lifting Engineer/Supervisors must be available throughout the work activity and
close monitoring to be ensured.
 Ensure that curing water should not fall on the road.

EMERGENCY PREPARDENESS PLAN

The purpose of emergency planning is to document set of actions and guidelines to be carried out in
the event of an emergency if it arises during the course of project operation in the project execution
area.
The Emergency Contact Numbers are kept up to date and conspicuously displayed
 First Aid Locations.
 Emergency Control Room Security
 Ambulance with Stretcher
 Fire Extinguisher
 Security

8. ENCLOSURES
 ITP
 Risk Assesment
 GFC Drawing
 Shop Drawing

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