Zuluf Temporary Facilities

Reference No: LI-0-887-TF9 Mechanical Works Rev: 00

Document Title: Method Statement for Telecommunication Tower Erection

Document Number: V-3200-TF9-A-1021

ZULUF TEMPORARY FACILITIES

Mechanical Works

Reference No.: LI-0-887-TF9

METHOD STATEMENT

FOR

Telecommunication Tower Erection

This document has been prepared by Attiq Ur Rehman Contracting Company for JGC.
It contains information that is Confidential and such information is intended to be for the exclusive use of the individual or entity named above.
It shall be neither shown to third parties nor used for purposes other than those for which it has been disclosed.
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 Zuluf Temporary Facilities
 

Reference No: LI-0-887-TF9 Mechanical Works Rev: 00

Document Title: Method Statement for Telecommunication Tower Erection

Document Number: V-3200-TF9-A-1021

TABLE OF CONTENTS

1 Purpose...........................................................................................................................................................................3
2 Scope of Work...............................................................................................................................................................3
3 Definitions......................................................................................................................................................................3
4 Reference Documents.................................................................................................................................................3
5 Duties and Responsibilities.......................................................................................................................................4
5.1 Project Manager............................................................................................................................................4
5.2 Construction Manager...................................................................................................................................5
5.3 QA/QC Manager............................................................................................................................................5
5.4 QA/QC Inspector...........................................................................................................................................5
5.5 Superintendent / Supervisors........................................................................................................................5
5.6 Safety Supervisor Responsibilities.................................................................................................................5
5.7 Surveyor........................................................................................................................................................5
6 Assembly and Erection of Steel Tower.................................................................................................................5
7 Alignment and Bolt Tightening.................................................................................................................................7
8 Field Modifications.......................................................................................................................................................8
8.1 Repair of Steel...............................................................................................................................................8
9 Grouting..........................................................................................................................................................................9
10 Lifting and Slinging...................................................................................................................................................10
11 Manual Handling.........................................................................................................................................................10
12 Quality Control and Inspection Test Plan............................................................................................................10
13 Equipment and Tools Used.....................................................................................................................................11
14 General HSE/Safety Requirements........................................................................................................................11
14.1 Working at High Elevation...........................................................................................................................11
Life line Cable and Railing Arrangement...................................................................................................................11
14.2 General Safety requirements......................................................................................................................12
15 Attachments.................................................................................................................................................................12

This document has been prepared by Attiq Ur Rehman Contracting Company for JGC.
It contains information that is Confidential and such information is intended to be for the exclusive use of the individual or entity named above.
It shall be neither shown to third parties nor used for purposes other than those for which it has been disclosed.
2
 Zuluf Temporary Facilities
 

Reference No: LI-0-887-TF9 Mechanical Works Rev: 00

Document Title: Method Statement for Telecommunication Tower Erection

Document Number: V-3200-TF9-A-1021

1 Purpose
The purpose of this method of statement is to define the methods that will be
adopted during the erection of telecommunication tower for the STC Connection DIAS
(Dedicated Internet Access Over Microwave) for construction activities of Temporary
Facilities at Zulf Project KSA

2 Scope of Work

This method of statement is made to enumerate the work procedure details involved
in the a s s e m b l y , erection and bolt tightening of telecommunication tower for the
Temporary Facilities at Zulf Project KSA

3 Definitions

Client: Saudi Aramco.

Contractor: JGC
Sub-contractor: ATTIQ UR REHMAN CONT.EST.

4 Reference Documents

4.1 Saudi Aramco Engineering Procedure

 SAEP‐302 Instructions for Obtaining a Waiver of a Mandatory Saudi Aramco

 Engineering Requirement Saudi Aramco References

4.2 Saudi Aramco Engineering Standards

 SAES-Q-001 Criteria for Design and Construction of Concrete Structures

 SAES-Q-005-Concrete Foundations

 SAES-Q-010 Cement Based, Non-Shrink Grout for Structural and Equipment

Grouting

 SAES-Q-011 Epoxy Grout for Machinery Support

 SAES-M-001 Structural Design for Non-Building Structures

4.3 Saudi Aramco Materials System Specification

 12-SAMSS-005 Marking of Metal Products

This document has been prepared by Attiq Ur Rehman Contracting Company for JGC.
It contains information that is Confidential and such information is intended to be for the exclusive use of the individual or entity named above.
It shall be neither shown to third parties nor used for purposes other than those for which it has been disclosed.
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 Zuluf Temporary Facilities
 

Reference No: LI-0-887-TF9 Mechanical Works Rev: 00

Document Title: Method Statement for Telecommunication Tower Erection

Document Number: V-3200-TF9-A-1021

 12-SAMSS-007 Fabrication of Structural and Miscellaneous Steel

 12-SAMSS-008 Erection of Structural and Miscellaneous Steel

4.4 American Welding Society (AWS)

 AWS D1.1/ D1.1M Structural Welding Code – Steel

 AWS D1.3/ D1. 3M Structural Welding Code – Steel Sheet

 AWS D14.1/ D14.1M Specification for Welding of Industrial and Mill Cranes
and Other Material Handling Equipment

4.5 Saudi Aramco Inspection Requirements

 Form 175-120100 Steel Structures

 Form 175-120500 Tower: Communication

4.6 Saudi Aramco Safety Standards

 Contractor Safety Manual (CSM)

 General Instructions (GI)
- G.I.02.100 PTW System
- G.I.07.025 Heavy Equipment operator testing and certification
- G.I.07.027 Crane Suspended personal platform man basket
- G.I.07.028 Crane Lifting Types and Procedure
- G.I.07.029 Rigging Hardware Requirements
- GI 150.003 & 150.006 Ionizing Radiation Protection Requirement
- G.I.08.001 Safety Requirements for Scaffolding

4.7 Inspection Checklists

 SAIC-M-2001
 SAIC-M-2006
 SAIC-M-2010

4.8 IFC Drawings

5 Duties and Responsibilities

5.1 Project Manager

The Project Manager shall be responsible for the over-all direction, coordination and

This document has been prepared by Attiq Ur Rehman Contracting Company for JGC.
It contains information that is Confidential and such information is intended to be for the exclusive use of the individual or entity named above.
It shall be neither shown to third parties nor used for purposes other than those for which it has been disclosed.
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 Zuluf Temporary Facilities
 

Reference No: LI-0-887-TF9 Mechanical Works Rev: 00

Document Title: Method Statement for Telecommunication Tower Erection

Document Number: V-3200-TF9-A-1021

Control of all the work activities attached and related to the structure work.

5.2 Construction Manager

The Construction Manager shall be responsible for the overall implementation and
monitoring of all the activities involved in Structure work.

5.3 QA/QC Manager

QA/QC Manager is responsible for the implementation of all required Quality

Control activities such as test and inspection for this particular job and keeps
record of its necessary documentation.

5.4 QA/QC Inspector

The QA/QC Inspector shall be responsible for the necessary inspections and tests
to be carried out for all the activities involved in Structure work.

5.5 Superintendent / Supervisors

The Superintendent/Supervisor are responsible to implement the proper working

procedure and strict- adherence of the HSE policy related to Structural Erection,
Lifting and House keeping the work explained herein.

5.6 Safety Supervisor Responsibilities

The Safety Supervisor shall review prior to the start of the work Safe Work Plan and
work permit, if required prior to submittal to the Contractor which must be
implemented and observed during the erection works.

The Safety Supervisor shall:

•Provide appropriate Safety and Health, accident prevention and investigation.

•Implement all safety aspects.
•Ensure work permit procedures are followed.

5.7 Surveyor
The surveyor makes arrangement to install structural members in proper levelling
and alignment.

6 Assembly and Erection of Steel Tower

6.1 The assembly and erection of structural steel shall be undertaken in accordance
This document has been prepared by Attiq Ur Rehman Contracting Company for JGC.
It contains information that is Confidential and such information is intended to be for the exclusive use of the individual or entity named above.
It shall be neither shown to third parties nor used for purposes other than those for which it has been disclosed.
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 Zuluf Temporary Facilities
 

Reference No: LI-0-887-TF9 Mechanical Works Rev: 00

Document Title: Method Statement for Telecommunication Tower Erection

Document Number: V-3200-TF9-A-1021

with 12-SAMSS-008 as well as per approved JSA. And also in accordance with
Occupational Safety and Health Administration Part 1926/Safety and Health/
Regulations for Construction Subpart R/Steel Erection.

6.2 Remove all dust, muds, sand and other foreign material accumulated thoroughly
before starting assembly and erection works.

6.3 Before starting the pre-assembly of the pre-fabricated structural materials,

dimensions will be checked for every member. Any deviations against the issued
drawings or defects on the members shall be immediately reported to Contractor /
Engineering.

6.4 The ground assembly of steel frames including ladder and guy wire carried out on
area near the foundation and pickup points of erection crane. A dedicated group
shall be assigned for the assembly of structural steels.

6.5 All column splices shall be field bolted.

6.6 The structural frame shall be assembled horizontally and shall consist of members
to form a complete assembled framing section. Assembly shall include the
preliminary tightening of bolts within the assembly frame.

6.7 Erector must see to it that the bearing surfaces and the bottom of baseplates are
cleaned prior to installation.

6.8 Temporary erection loads or permanent loads shall not be placed on any
incomplete portions of the structure being erected unless Subcontractor can
demonstrate by analysis that the contemplated action is safe.

6.9 When the assembled frame is placed at its location, guy wires with sufficient length
shall be used to secure the frame. Make sure they will not slide down when
supporting the assembled frame at its vertical position. Provide rubber softener on
column edges to protect from direct contact with slings

6.10 Erect pre-assembled frame by observing all applicable safety requirements of the
job - operating radius is clear of unauthorized personnel, wind speed below 20MPH,
pre-lift operation checklist accomplished / followed.

6.11 Erect the next succeeding frame by steps. After erecting the second steel frame,
install the main connecting plates(cleat, cover plate, pack plate) and bolts between
the two frame structures. These connecting beams shall be installed by following
steps below:

6.12 Before the frame is lifted up, position the man lifts in safe locations for all ends in
preparation for bolting.

This document has been prepared by Attiq Ur Rehman Contracting Company for JGC.
It contains information that is Confidential and such information is intended to be for the exclusive use of the individual or entity named above.
It shall be neither shown to third parties nor used for purposes other than those for which it has been disclosed.
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 Zuluf Temporary Facilities
 

Reference No: LI-0-887-TF9 Mechanical Works Rev: 00

Document Title: Method Statement for Telecommunication Tower Erection

Document Number: V-3200-TF9-A-1021

6.13 During bolting the erectors can use spud wrench and drift pin to insert at least two
structural bolts with washer and nuts. Spud wrench will be string tied to prevent
accidental drops.

6.14 Upon completing bolting / confirming stable condition of the frame, keep the slings
and make connections by using the man lift.

6.15 Erector will use man lift at four ends of frame. (note: man basket is only used as a
last option after all other options are proven to be impossible. When using of man
basket Critical Lifting Plan shall be prepared. Ensure that the crane and man basket
are certified for man riding
7 Alignment and Bolt Tightening

Alignment

7.1 After the completion of erection, structures should be aligned vertically and
horizontally. Calibrated Theodolite will be used for alignment. Use appropriate chain
block, turnbuckles and guy wires to correct misalignment tolerances should be as
per Aramco standards.

7.2 Drift pin shall be used for initial align of beam, girder, or bracing bolt hole
connections.

7.3 All temporary erection bolts must be removed and replace with high-strength bolt.

7.4 Bolts that shall be incorporated to the structure; pre-installation procedure

verification must be performed. “Except for ASTM A307 Bolts”

7.5 Used bolts, nuts shall not be use and a separate container will be provided to avoid
mixing with the new bolt.

7.6 Hammering of high-strength bolt shall not be permitted.

7.7 Prior to installation of bolt, faying surfaces and surfaces adjacent to the bolts and
nuts shall be cleaned.

7.8 Align all bolt holes to permit insertion of the bolts without undue damage to the
threads.

7.9 All bolted connections shall be, in systematic manner, “snug-tight” to impact the joint
from the most rigid part toward the free edges.

7.10 Bolt shall be progressively sequentially tightened frim the most rigid part of the joint
to avoid relaxation of previously tightened bolt.

This document has been prepared by Attiq Ur Rehman Contracting Company for JGC.
It contains information that is Confidential and such information is intended to be for the exclusive use of the individual or entity named above.
It shall be neither shown to third parties nor used for purposes other than those for which it has been disclosed.
7
 Zuluf Temporary Facilities
 

Reference No: LI-0-887-TF9 Mechanical Works Rev: 00

Document Title: Method Statement for Telecommunication Tower Erection

Document Number: V-3200-TF9-A-1021

7.11 A mechanical wrench shall be used if necessary

7.12 All bolts should be tightened to snug-tight condition during alignment. The snug-
tightened condition is the tightness that is attained with a few impacts by an
impact wrench or the full effort of an ironworker using an ordinary spud wrench to
bring the connected plies into firm contact.

7.13 After tightening all bolts shall be marked to be easily identified by the
inspector during inspection.

8 Field Modifications

8.1 Repair of Steel

8.1.1 QC Inspector should inspect all the prefabricated steel members which are
delivered at the lay down area before releasing for erection, if the damaged
material cannot be repaired at site, the material should be rejected and re-
fabricated by vendor. Deformed members shall be duly corrected in such manner
that the total texture of the material is not damaged.

8.1.2 Welder qualification shall be according to AWS D1.1 or ASME IX.

8.1.3 Enlargement of holes shall be made by reaming or drilling only. Flame cutting,
burning, g o u g i n g , c h i p p i n g o r d r i f t p u n c h i n g s h a l l n o t b e permitted.

8.1.4 The galvanized coating damaged by cutting and welding shall be cleaned
thoroughly before repairing.

8.1.5 Paint containing organic zinc dust will be used for repairing damaged
galvanized coatings which provide a dried film that contains not less than 80%
zinc dust by weight. Paint shall be applied by spraying, roller or by brush to the
prepared area. Recommendations by the paint manufacturer should be followed
during paint application according to SAES-H-101v.

This document has been prepared by Attiq Ur Rehman Contracting Company for JGC.
It contains information that is Confidential and such information is intended to be for the exclusive use of the individual or entity named above.
It shall be neither shown to third parties nor used for purposes other than those for which it has been disclosed.
8
 Zuluf Temporary Facilities
 

Reference No: LI-0-887-TF9 Mechanical Works Rev: 00

Document Title: Method Statement for Telecommunication Tower Erection

Document Number: V-3200-TF9-A-1021

9 Grouting

9.1 Foundations shall be released for grouting along with the release note from
structural department with alignment and bolt tightening inspection acceptance
records.

9.2 Once again foundations shall be cleaned thoroughly.

9.3 Formwork shall be prepared and installed on the concrete pedestals.

9.4 Continuous wetting of foundation top surface shall be carried out for minimum of
24 hours.

9.5 Excess water on the foundation top surface shall be removed but it should be in
moist condition.

9.6 Non-shrink grouting mixture shall be prepared as per the vendor specification and
shall be poured on the pedestal below the column base plate. Grout will be applied
according to SAES-Q-010 Cement Based, Non-Shrink Grout for Structural and
Equipment Grouting.

9.7 Thickness of the grout to be followed by as per IFC drawings.

9.8 Formwork can be removed after 24 hours of grouting.

9.9 The grouted area shall be cured for a minimum period of 72 hours. When the
water/cement ratio is 0.4 or less, the grout shall be continuously water cured for a
minimum of seven days. Please see attached MDS for grouting.

Fig 2. Schematic diagram of tower base joint with foundation

This document has been prepared by Attiq Ur Rehman Contracting Company for JGC.
It contains information that is Confidential and such information is intended to be for the exclusive use of the individual or entity named above.
It shall be neither shown to third parties nor used for purposes other than those for which it has been disclosed.
9
 Zuluf Temporary Facilities
 

Reference No: LI-0-887-TF9 Mechanical Works Rev: 00

Document Title: Method Statement for Telecommunication Tower Erection

Document Number: V-3200-TF9-A-1021

10 Lifting and Slinging

10.1 Lifting crane shall be selected based on the weight of item to be lifted and the
working radius. The swing area of the crane will be checked for any obstructions,
prior to start of the works all the rigging tools will be made available at the erection
site prior to start of the rigging activities.

10.2 Only Aramco approved operator and riggers shall be deployed for the lifting activities

10.3 Crane must finish contractor inspection programs and must have a valid 3rd party
certification

10.4 All lifting gears must be inspected by Aramco approved riggers

10.5 Any attachments to the crane boom (fly jib) for lifting shall be in coverage of critical lifting
plan and rigger 1

10.6 All the rigging personnel shall take up their designated position & the signalman
shall be identified with a distinguished vest.

10.7 Other means of communication between the rigger, crane & man-lift operator will
be provided where necessary.

10.8 Crane lifting must be in compliance with GI 7.028 (Crane lifting types and
Procedures)

11 Manual Handling
Telecommunication tower steel structure will be erected by man-power on the
ground as a frame section by section. Each section frame will be approximately
between 6 to 12 meters. After erection on ground frame going to be lifted by crane.

12 Quality Control and Inspection Test Plan

12.1 All necessary inspections shall be carried out as per approved ITP by Contractor.
All bolts checked by visual inspection.
12.2 Prior to work, related request for inspection (RFI) must be approved by Contractor
/ Company

12.3 Certified test reports for each material specified herein showing the results of the
manufacturer’s test shall be submitted. These reports shall show that the
materials comply with the approved Company standard and specifications.
This document has been prepared by Attiq Ur Rehman Contracting Company for JGC.
It contains information that is Confidential and such information is intended to be for the exclusive use of the individual or entity named above.
It shall be neither shown to third parties nor used for purposes other than those for which it has been disclosed.
10
 Zuluf Temporary Facilities
 

Reference No: LI-0-887-TF9 Mechanical Works Rev: 00

Document Title: Method Statement for Telecommunication Tower Erection

Document Number: V-3200-TF9-A-1021

13 Equipment and Tools Used

 Crane (capacity of crane depend on tower height)

 Man lift
 Grinding machine
 Welding Machine
 Chain Block / Turnbuckle
 Guy Wire
 Slings, Shackles, Wire ropes etc.

14 General HSE/Safety Requirements

14.1 Working at High Elevation

Life line Cable and Railing Arrangement

14.1.1 For pipe railings, posts and top and intermediate railings shall be at
least 1 1/2 inches nominal OD diameter with posts spaced not more
than 8 feet on centers.
14.1.2 For structural steel railings, posts and top and intermediate rails shall
be of 2 inch by 2 inch by 3/8 inch angles or other metal shapes of
equivalent bending strength, with posts spaced not more than 8 feet on
centers.

14.1.3 For wire rope railings, the top and intermediate railings shall be at
least 1/2-inch fiber core rope, or the equivalent to meet strength
factor and deflection. Posts shall be spaced not more than 8 feet on
centers. The rope shall be stretched taut, so as to present a minimum
deflection.

14.1.4 The anchoring of posts and framing of members for railings of all types
shall be of such construction that the completed structure shall be
capable of withstanding a load of at least 200 pounds applied in any
direction at any point on the top rail, with a minimum of deflection.
Railings receiving heavy stresses from employees trucking or handling
materials shall be provided additional strength by the use of heavier
stock, closer spacing of posts, bracing, or by other means.

14.1.5 A vertical lifeline, horizontal lifeline, or overhead structural

anchorage capable of supporting 2,300 kilograms (5,000 pounds) shall
be provided where it is not practically possible to have handrail/fall
This document has been prepared by Attiq Ur Rehman Contracting Company for JGC.
It contains information that is Confidential and such information is intended to be for the exclusive use of the individual or entity named above.
It shall be neither shown to third parties nor used for purposes other than those for which it has been disclosed.
11
 Zuluf Temporary Facilities
 

Reference No: LI-0-887-TF9 Mechanical Works Rev: 00

Document Title: Method Statement for Telecommunication Tower Erection

Document Number: V-3200-TF9-A-1021

protection system.

14.1.6 When lifelines are used, they shall be fastened to fixed safe point(s) of
anchorage capable of supporting 2,300 kilograms (5,000 pounds), shall
be independent, and shall be protected from sharp edges and
abrasion.

14.1.7 Horizontal and vertical lifelines shall be made from 10 mm (3/8-inch)

min diameter wire rope. Other materials such as manila, nylon, or
polypropylene rope shall not be used as a lifeline. Turn buckle/post will
be provided for fixing the rope to avoid defluxion or sagging more
than 300mm.

14.1.8 Weekly inspection program will be conducted for the lifeline

arrangements.

14.1.9 Horizontal lifelines shall be installed at the highest feasible point,

preferably above shoulder height. Horizontal lifelines shall be
maintained with sag at the center no greater than 300(12 inches) for
every 10 meters (33 feet) of lifeline length between attachment points.

14.2 General Safety requirements

14.2.1 Contractor / Subcontractor Safety Supervisor shall carry out the safety
site inspections to ensure that safety requirements laid out in the safe
work plan are followed prior to start work.

14.2.2 Barricading of “swing” areas of all lifting equipment shall be checked

prior to the commencement of work.

14.2.3 All the lifting, shifting equipment, tools and tackles shall be inspected
and color coded / certified by Subcontractor / Contractor safety
department prior to give clearance for erection.

14.2.4 The activity shall be having a necessary work permit and work
permit certificates.
14.2.5 Other controls in response to the drastic spread of the COVID-19 virus
shall be in place and implemented according to the local authorities
and international guidelines as mentioned in the revised ERP and HIP

15 Attachments
Job Safety Analysis Attached

This document has been prepared by Attiq Ur Rehman Contracting Company for JGC.
It contains information that is Confidential and such information is intended to be for the exclusive use of the individual or entity named above.
It shall be neither shown to third parties nor used for purposes other than those for which it has been disclosed.
12