METHOD STATEMENT

For

FABRICATION, PAINTING AND ERECTION FOR RIGGING SYSTEM

Submitted by:

Hussain Omar Alathas Factory co.

Prepared By Approved By

Name Mohanraj Mohammad Fayed

Position QA QC Manager Plant Manager

Signature & Date

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 LIST OF CONTENT

Section Title Page

1.0 INTRODUCTION 4

2.0 HEALTH AND SAFETY POLICY 4

2.1 SAFE CONDITION SIGNS 5

3.0 FABRICATION PROCEDURE 5

3.1 SURFACE CLEANING 6

3.2 CUTTING AND MACHINING 6

3.2.1 SHEARING AND CROPPING 6

3.2.2 FLAME CUTTING OR BURNING 6

3.2.3 ARC PLASMA CUTTING 7

3.2.4 COLD SAWING 7

3.3 PUNCHING AND DRILLING 7

3.4 WELDED CONNECTIONS 7-8

3.4.1 DEFECTS IN WELDS 8-9

3.5 FINISHING 10

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 3.6 BLASTING 10

4.0 PAINTING 10

5.0 QUALITY CONTROL IN FABRICATION 10

5.1 FABRICATION 10

5.1.1 IMPERFECTIONS IN FABRICATION 10

5.1.2 WELDED JOINTS 11

6.0 ERECTION 11-12

6.1 GENERAL 12

6.2 WELDING 13

6.3 PAINTING PROCEDURE 12-13

7.0 SUMMARY 13

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 FABRICATION AND ERECTION OF RIGGING SYSTEM:

1.0 INTRODUCTION

To assure that steel structure for rigging system is fabricated and erected in accordance
with industry codes and standards, and relevant project specifications, IFC drawings and
Client Specification requirements.

This procedure outlines the job site controls employed for rigging steel Construction for
fabrications, installation, and construction practices to meet the contractual requirements.

2.0 HEALTH AND SAFETY

HEALTH AND SAFETY POLICY

AFCO, recognizes its duty to comply with the HEALTH and SAFETY at work as
far as is responsibly practicable
1 Provide adequate resources to maintain health and safety.
2 Carry out risk assessments and review them when necessary.
3 Provide
health.
and maintain systems of work which are safe and without risk to
Establish arrangements for the use, handling, storage and transport of articles
4 and substances provide for use at work, which are safe and without risk to
health.
Provide employees with such information, instruction, training and
5 supervision as is necessary to secure their safety and health at work and that
of others who may be affected by their actions.
6 Carry out health surveillance, where required.
7 Ensure that all machinery, plant and equipment are maintained in a safe
condition
8 Make adequate provision and arrangements for welfare facilities at work.
9 Keep the work place safe and ensure that access and egress are safe and
without risk.
10 Monitor safety performance to maintain agreed standards.
The duties of employees are to:
1 Take reasonable care of their own health and safer, and that of others who
may be affected by their acts or omissions at work.
2 Co-operate with others in the company to fulfill our statutory duties.
3 Not interfere with, misuse or willfully damage anything provided in the
interest of health and safety.
To ensure that this policy is effective, we will:
1 Review it annually, or on significant changes is our business.
2 Make any such changes known to employees.
3 Maintain procedures for communication and consultation between| Palla glevels
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of staff on matters of health, safety and welfare.
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 2.1

3.0 FABRICATION PROCEDURE

Rigging system members fabrication can be carried out in shop or at the

construction site. Fabrication of these members work carried out in shops is precise
and of assured quality, whereas field fabrication is comparatively of inferior in
quality.

Rigging system members work passes through various operations during the course
of its fabrication. Generally, the sequence of activities in fabricating shops is as
shown in Table1. The sequence and importance of shop operations will vary
depending on the type of fabrication required. All these activities are explained
briefly in the subsequent parts of the section.

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3.1 SURFACE CLEANING

Rigging members from the rolling mills may require surface cleaning to remove mill
scale prior to fabrication and painting (according to the high performance coatings-
099600).

Blast cleaning is the accepted way of carrying out surface preparation in a well-run
fabrication shop. Abrasive particles are projected on to the surface of the steel at high
speed by either compressed air or centrifugal impeller to remove rust and roughen the
surface before applying the coating. By using steel shot or slag grits, both of which have
an angular profile, surface oxides are removed and a rougher surface is obtained to
provide an adequate key for metal spraying or special paint. Depending upon the increase
in the quality of the cleaned surface, the blast cleaning.

3.2 CUTTING AND MACHINING

Following surface preparation, cutting to length is always the first process to be carried
out, and this is done by any of the following methods.

3.2.1 SHEARING AND CROPPING

Sections/Plates can be cut to length or width by cropping or shearing using hydraulic

shears. Long plates or sections can be shaped by CNC Processing/ cutting Machine.

3.2.2 FLAME CUTTING OR BURNING

In this method, the steel is heated locally by a pressurized mixture of oxygen and a
combustible gas such as propane, which passes through a ring of small holes in a cutting
nozzle. The heat is focused on to a very narrow band and the steel melts at 1500 C when
a jet of high-pressure oxygen is released through a separate hole in the centre of the
nozzle to blast away the molten metal in globules. The desired cuts are obtained quickly
by this process. However due to a rapid thermal cycle of heating and cooling, residual
stresses and distortion are induced and hence structural sections that are fabricated using
flame cutting are treated specially in the design of steel for rigging system members.

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3.2.3 ARC PLASMA CUTTING

In this method, the cutting energy is produced electrically by heating a gas in an electric
arc produced between a tungsten electrode and the work piece. This ionizes the gas,
enabling it to conduct an electric current. The high-velocity plasma jet melts the metal of
the work piece. The cut produced by plasma jet is very clean and its quality can be
improved by using a water injection arc plasma torch. Plasma cutting can be used on
thicknesses up to about 150 mm but the process is very slow.

3.2.4 COLD SAWING

All saws for structural applications are mechanical and feature some degree of computer
control (CNC). There are three forms of mechanical saw - circular, band and hack. The
circular saw has a blade rotating in a vertical plane, which can cut either downwards or
upwards, though the former is more common. The saw blade is a continuous metal edged,
with cutting teeth, which is driven by an electric motor. They have more productivity
than band saws.

3.3 PUNCHING AND DRILLING

Most fabrication shops have a range of machines, which can form holes for connections
in steelwork. The traditional drilling machine is the radial drill, a manually operated
machine, which drills individual holes in steel work. But this method has become too
slow for primary line production. Therefore, larger fabricators have installed CNC
(Computer Numerically Controlled) tooling, which registers and drills in response to
keyed in data. These can drill many holes in flanges and webs of rolled steel sections
simultaneously. It is also possible to punch holes, and this is particularly useful where
square holes are specified such as anchor plates for foundation bolts. While this method
is faster compared to drilling, punching creates distortion and material strain hardening
around the holes, which increase with material thickness. Its use is currently restricted to
smaller thickness plates. In order to reduce the effect of strain hardening and the
consequent reduction in ductility of material around punched holes, smaller size (2 mm to
4 mm lesser than final size) holes are punched and subsequently reamed to the desired
size.

3.4 WELDED CONNECTIONS

Welding is used extensively for joining metals together and there is no doubt that it has
been a most significant factor in the phenomenal growth of many industries. The different
terminology used in welds is explained in AWS D1.1 / WPS. A welded joint is made by
fusing (melting) the steel plates or sections along the line of joint. The metal melted from
each member of the joint unites in a pool of molten metal, which bridges the interface. As
the pool cools, molten metal at the fusion boundary solidifies, forming a solid bond with
the parent metal. When solidification completes, there is a continuity of metal through the
joint.

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There are five welding process regularly employed namely:
(i) Shielded Metal Arc Welding (SMAW)
(ii) Submerged-Arc Welding (SAW)
(iii) Manual Metal-Arc welding (MMA)
(iv) Metal-Active Gas welding (MAG)
(v) Stud welding

In our Factory we are using Shield Metal Arc Welding (SMAW) and Flux Cored Arc
Welding (FCAW).

3.4.1 DEFECTS IN WELDS

Faulty welding procedure can lead to defects in the welds, thereby reducing the strength
of the weld.
Fig.8 shows some of the common defects in welds. Some of these are:
(i) Undercut
(ii) Porosity
(iii) Incomplete Penetration
(iv) Lack of side wall fusion
(v) Slag inclusions
(vi) cracks

All these weld defects are discussed in the chapter on Weld Static and Fatigue strength
I. It should be emphasized that a theoretical 100% error free weld is not achievable
in practice. While good quality welds are the priorities of welders and weld inspectors,
minor defects do normally creep in. Hence these defects are assessed during a weld
inspection.

If the defects are within acceptable limits, they are accepted. If not, alternative measures
of rectification may have to be carried out. Table 2 shows nature of some of the defects
and their acceptability limits.

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3.5 FINISHING

Rigging System members shall be transmitted to finishing area. Finishing is performed

by chisel with help of hammer or by grinding machine to remove the spatters, slag and
any other mechanical damage before sent to blasting zone.

3.6 BLASTING

Blast Cleaning according to high performance coatings (099600) is the most effective method
of removing mill scale. This is an essential treatment for the successful use of high
performance coatings of all members. Blast cleaning is specified to an agreed standard with
the Client preferably with reference to a visual standard, and the profile or degree of
roughness specified and controlled during the operation.

4.0 PAINTING

Painting is the principal method of protecting all members from corrosion. Paints are usually
applied according to the high performance coatings (099600).

5.0 QUALITY CONTROL IN FABRICATION

Quality assurance during fabrication assumes utmost importance in ensuring that the
completed structure behaves in the manner envisaged during design stage. Any deviation
from these design considerations as reflected in detail drawings may introduce additional
stresses to the structure and affect its strength and durability. This section discusses the
relevant aspects in fabrication and erection, which need to be considered to achieve the
desired quality.

5.1 FABRICATION

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.

5.1.1 IMPERFECTIONS IN FABRICATION

Steelwork cannot be fabricated to exact dimensions and some degree of Imperfection is
bound to occur during fabrication process. The limits of various Imperfections are spelt out in
the specifications. In the design, these are accounted by adopting a factor of safety for
material. However, in some components an increase of Imperfection beyond these limits may
lead to reduction in the strength and durability of The structure e.g., imperfections on the
straightness of the individual flanges of a rolled Beam results in the reduction of strength
materials. As a rule all columns and struts should be checked for straightness on completion
of fabrication.

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5.1.2 WELDED JOINTS

As presented in the previous sections, welded joints are very important as far as the
Quality control of the joints is concerned. It is well known that joints are the last straw of
Strength in steel work for rigging system. Any poor quality weld would detrimentally affect
the Joint and in turn affect the performance of the whole structure itself.

6.0 ERECTION

6.1GENERAL

Erection of rigging system works is the process by which the fabricated steel members
are assembled together. The erection is normally carried out by the erection department.
Generally the steps that are involved in the erection of metals are shown in Table 3. The
erection process requires considerable planning in terms of material delivery, material
handling, member assembly and member connection. Proper planning of material
delivery would minimize storage requirement and additional handling from the site
storage, particularly heavy items. Erection of rigging members could be made safe and
accurate if temporary support, false work, staging etc. are erected.
Before erection the fabricated materials should be verified at site with respect to mark
numbers, key plan and shipping list. The structural components received for erection
should be stacked in such a way that erection sequence is not affected due to improper
storing. Care also should be taken so that rigging system components should not come in
contact with earth or accumulated water. Stacking of the members should be done in such
a way that, erection marks and mark numbers on the components are visible easily and
handling does not become difficult. From the earlier discussion it should emphasized that
safe transportation of fabricated items to the site, their proper storage and subsequent
handling are the pivotal processes for the success of fabrication of steel work.

The erection drawing should reach the site of construction well in advance to plan the
erection sequence and material handling. Erection should be carried out with the help of
maximum possible mechanization. Normally anyone or more of the material handling
systems, such as crane mounted on rails, crawling crane, pneumatic tire mounted crane,
etc.. May be used for handling the material. Details of the above said erection equipments
can be found in any standard textbooks on construction equipment.

A variety of methods can be employed for the erection of a structure. Normally, the
selection of the method is influenced by the type of the structure, site conditions,
equipment, quality of skilled labor, etc. available to the erector.

However, regardless of the method adopted the main aim during erection is the safety and
Preservation of the stability of the structure at all times. Most structures which collapse
do so during erection and these failures are very often due to a lack of understanding on
Someones part of what another has assumed about the erection procedure.

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All the erection equipment tools, shackles, ropes etc. should be tested for their load
Carrying capacity. Such tests if needed may be repeated at intermediate stages also.

Application of a final coat painting.

6.2 Fabrication & Welding

Mark the connecting members as per drawing.

All the cutting operation as per requirement shall be carried out after getting the clearance
from the inspection authority. All the cutting operation shall be carried out by gas cutting
method on all the four side. Grind the cut edges smooth to remove burrs, slag & Painting.
Structural item of the rigging system members shall be fabricated as per drawing.

At the time of welding there is to be no paint, other than suitable prefabrication primer,
Within 50mm of the weld.

Apply and remove temporary protection before welding if this is necessary to ensure
That rusting does not occur to a level beyond that allowed by the Specification.

Removal of slag from weld and the cleaning of a weld.

6.3 PAINTING PROCEDURE

1. Check weld appearance and workmanship of welded structure, grinding of sharp and
roughness of cut edges, burrs and removal of slag and weld spatters.

2. Every possible precaution shall he taken to ensure that the damaged surface(s) shall be
thoroughly clean, dry, and free from condensation, moisture, dust, oil grease, rust, dirt
and other contaminants before the application of the Paint or touch-up/repair processes.

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3. Hand and Power tool cleaning and painting shall not be conducted when the surfaces
are less than 3 C above dew point or when the relative humidity of the air is greater than
85%.

4. Surface preparation, whenever possible, shall be carried out by hand or power tool
cleaning shall be applied. This shall be followed by solvent cleaning prior to painting.

5. Painting is the principal method of protecting all members from corrosion. Paints are
usually applied according to the high performance coatings (099600).

6. The use of brushes or rollers for touch-up/repair on localized damaged surfaces where
proper coating by spray application is not feasible may be used upon company approval.
When using brushes, ensure that a smooth coat, as uniform in thickness as possible, is
obtained with no deep or detrimental brush marks. Paint shall be worked into all crevices
and corners. Runs and sags shall be brushed out immediately during paint application.

7.0 SUMMARY

In this chapter the importance of fabrication and painting in steelwork for rigging system
works are underlined. The various tasks involved in fabrication are discussed. The joints,
which are important components in steelwork for rigging system works, are explained, with a
special emphasis on Welded joints. Thus an overall view of the fabrication and painting of
rigging system works members are covered in this report.

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