007-MS For Structural Steel Assembly Warehouse, Workshops PDF

Pearl GTL
Project
Shell Project No: HP-3000-QAT
Project Document Number: T.4.250.902
Purchase Order Number:
2MH127
Tag/Item Number(s):
N/A
Unit(s):
ASU
PCWBS:
LINDE ENGINEERING
Contractor Project No :
Project Rev.: B
Page 2 of 23
5887
QATAR SHELL GTL PROJECT (PEARL)

C2 AIR SEPARATION UNITS CONSTRUCTION
19.07.2008
Company Comments Incorporated
AG
MK
AG
CCI
16.03.2008
Issued for Company Comments (Included fixing of

anchor bolts)
AG
MK
AG
ICC
24.04.2008
Ready For Construction
AG
EE
ZG
RFC
06.03.2008
Issued for Company Comments
AG
EE
ZG
ICC
26.02.2008
Issued for Review
AG
EE
ZG
IFR
24.02.2008
Issued for Internal Review
AG
EE
ZG
IIR
Date
Description
GAMA
Rev.
No.
Project
Rev
No.
Prepared Checked Approved

By
By
By
ORIGINATOR
Status
Document Title:
LINDE ENGINEERING AG
METHOD STATEMENT FOR STRUCTURAL STEEL

ASSEMBLY WAREHOUSE, WORKSHOPS
Document No.
Contractor
LOC470
Gama Qatar Co. W. L. L.
GAM
MTS
MEC
GTL
007
Org.
Code
Doc.
Type
Disc.
Code
Geogr.
Area
Seq.
No
Rev.
No
Project Document Number: T.4.250.902
Vendor Code
Rev No: B
Doc. Title
Q A T A R
Date/Rev. No :

19.07.2008 (Rev. F)
TABLE OF CONTENTS
1
PURPOSE .......................................................................................................................................................................... 5
SCOPE ................................................................................................................................................................................ 5
REFERENCES .................................................................................................................................................................. 5
DEFINITIONS .................................................................................................................................................................... 6
EQUIPMENT & MATERIAL ............................................................................................................................................ 6
PERSONNEL ..................................................................................................................................................................... 6
MATERIALS ...................................................................................................................................................................... 6
RESPONSIBILITY ............................................................................................................................................................ 6
8.1
MECHANICAL WORKS MANAGER
8.2
STEEL STRUCTURE SUPERINTENDENT
METHOD OF EXECUTION ............................................................................................................................................. 7

9.1
PRE-COMMENCEMENT WORKS
9.1.1 WORK PERMIT
9.1.2 TRAFFIC MANAGEMENT PLAN
9.1.3 HANDLING, STORAGE AND PRESERVATION
9.1.4 EQUIPMENT AND PERSONNEL
10 PREASSEMBLY & ERECTION ..................................................................................................................................... 7

10.1.1STEEL STRUCTURE ON FOUNDATION OR PEDESTAL
10.1.2PRE-STABILIZATION
10.1.3FINAL STABILIZATION & COMPLETING
10
10.1.4PROCEDURE FOR USING EXPANSION ANCHOR BOLTS
10
10.1.5PROCEDURE FOR USING ADHESIVE ANCHOR & FOIL CAPSULE
10
11 QUALITY ASSURANCE ............................................................................................................................................... 10

12 HSSE ................................................................................................................................................................................. 10
13 ATTACHMENTS ............................................................................................................................................................. 11
13.1 JOB SAFETY ANALYSIS
T.4.250.902 REV-B
11
Page 4 of 23
Doc. Title
Q A T A R
Date/Rev. No :

19.07.2008 (Rev. F)
1 PURPOSE
The purpose of this method statement is to outline the general requirements & precautionary
measures which will be taken into consideration for the structural steel assembly & erection
works and also to understand the expansion anchor bolts will be installed prior to the erection of
steel substructures intended for the construction of storage of storage area of the warehouse at
TSF areas.
2 SCOPE
This method statement identifies the general steps, arrangements & precautions for the
Structural Steel Assembly, Erection works, fixing of expansion anchor bolts to be used for the
mezzanine floor of the warehouse at TSF areas.
3 REFERENCES
T-4.234.067
T-4.219.583
T.4.231.527
T-4.129.868
T-4.129.859
T-4.219.590
T.4.250.938
T.4.129.855
T.4.129.859
T.4.129.854
T.4.129.850
T.4.129.865
T.4.129.866
T.4.129.861
T.4.129.867
T.4.129.853
T.4.129.863
T.4.129.873
T-4.250.917
T-4.250.907
ASTM A325M
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
ASTM A490 M
ASTM A307M
ASTM A563M
ASTM F959M
:
:
T.4.250.902 REV-B
MS for Surveying
HSSE Meetings, Inspections and Walk through Plan
General Notes For Structural Steel
Work at Height - Scaffolding
Lifting Procedure General
Scaffolding Procedure
General Welding Procedure
Emergency Response
Lifting Operations
Risk Assessment
Accident/Incident/Near Miss Reporting and Investigation
Portable Power Tools
Use of Grinding Machines and Abrasive Wheels
Working with Electricity
Hand Tools
Personal Protective Equipment
Welding and Flame Cutting
Safety Induction And HSSE Training
ITP for Structural Steel
QCP for Structural Steel
Standard Specification for High Strength Bolts for Structural
Steel Joints
Standard Specification for High Strength Steel Bolts, Classes
10.9 and 10.9.3, for Structural Steel Joints
Standard Specification for Carbon Steel and Studs, 60,000
PSI Tensile Strength (Ordinary Strength Bolts)
Standard Specification for Carbon & Alloy Steel Nuts (Metric)
Compressible-Washer-Type Direct Tension Indicators
Page 5 of 23
Doc. Title
Q A T A R
Date/Rev. No :

19.07.2008 (Rev. F)
4 DEFINITIONS
Company
Contractor
Sub Contractor
Contract
QCP
ITP
QA/QC
RLIC
RAT
TBT
JSA
:
:
:
:
:
:
:
:
:
:
:
QSGTL or its PMC
Linde Engineering AG
Gama Qatar Co. W.L.L
GTL Project
Quality Control Procedures
Inspection and Test Plan
Quality Assurance / Quality Control
Ras Laffan Industrial City
Risk Assessment Team
Tool Box Talk
Job Safety Analysis
5 EQUIPMENT & MATERIAL
Mobile crane 60 Ton

Manlift, Man-basket
Trifore
Hubzug (come along)
Hand tools (wrenches, pliers, scissors)
Rigging gear (Slings, shackles, )
Welding machine
Surveying equipment & instruments
Tower Light
Safety Block
Safety Belt with double Lanyard
Safety Belt
Trailer
Magnetic Drills/Hand Drills
Chipping Hammer
Generator
Spreader Beam
Banksmen
Rigger
Scaffolder
First Aid Worker
HSE personnel
6 PERSONNEL
Site Engineer
Foreman
Survey Team
Steel Erector
Welder
Helper
7 MATERIALS
Fabricated structural steel members

Fasteners & welding rods
8 RESPONSIBILITY
8.1 MECHANICAL WORKS MANAGER
The Mechanical works Manager will provide inputs to the project execution plan to ensure
that the erection, lifting strategies & philosophy are addressed.
T.4.250.902 REV-B
Page 6 of 23
Doc. Title
Q A T A R
Date/Rev. No :

19.07.2008 (Rev. F)
8.2 STEEL STRUCTURE SUPERINTENDENT

The Steel Structure Superintendent is responsible for the overall management of the project
construction team to ensure that safe and effective operations are conducted and properly
documented.
9 METHOD OF EXECUTION
9.1
PRE-COMMENCEMENT WORKS
9.1.1 WORK PERMIT

The erection operation of a steel structure starts with a request for a permit to work. Only
after issuance of the related permit will the execution of the work start.
9.1.2 TRAFFIC MANAGEMENT PLAN
Works shall not interrupt any kind of vehicle traffic on any access road leading to any
gates. In case of interruption a revised traffic management plan shall be provided.
Care will be shown to minimize impact onto other works but not so much as to hinder
SUBCONTRACTOR erection works. Coordination of subcontractor's works at site is under
CONTRACTORS scope.
9.1.3 HANDLING, STORAGE AND PRESERVATION
Handling, storage, preservation and protection will be carried out as per project
specification.
All small components like high strength bolts, nuts, washers, etc will be stored in a water
tight and dry place.
Upon receiving the materials from contractor the different structural members will be
visually checked by GAMA QATAR for any visual defects or apparent damage.
The threaded portion of anchor bolts will be kept clean and protected from damage.
9.1.4 EQUIPMENT AND PERSONNEL
All equipment shall be inspected and approved according to T-4.129.873 and all personnel
shall be inducted and trained before commencement of work.
10 PREASSEMBLY & ERECTION

The preassembly and erection will be done in basically the following steps: preassembly on the
ground, erection with crane(s), stabilization of erected pieces, general cleanup.
All erection works will be done with the latest approved IFC drawings.
Before assembly of any structural steel element; position and level of anchor bolts will be
checked. True level of a base plate will be obtained with the use of shimming plates.
Surveyors will paint marks on the foundations denoting the axes and levels to be used. These
target marks will be colored for visibility.
Where possible, preassembly of the steel structure elements will be done close to the
T.4.250.902 REV-B
Page 7 of 23
Doc. Title
Q A T A R
Date/Rev. No :

19.07.2008 (Rev. F)
foundations to minimize handling needs preferably in a position where the crane used for the
assembly can be used for the erection as is.
Erection of the preassembled parts will be done with cranes.
Adequate safe lifting capacity of the cranes is to be confirmed from the load charts of the
cranes to be submitted for approval, before the start of the respective work.
During the actual lifting activity, a maximum of 80% of the load chart value will be permitted.
Heavier lifting work will require Subcontractor to submit and have approved a heavy lift plan to
Contractor specifically for the said lifting activity. The Lifting/Rigging Superintendent will
supervise lifting activities.
The area where the crane is positioned must be suitable for the purpose. There should not be
deep excavations close enough to the crane to destabilize it and the ground must be firm
enough to prevent the crane from sinking. To spread the load and further stabilize the crane
steel sheets or pads will be used if required. A soft barricade will be erected around the crane
and signs posted to clearly define the work area.
All safety requirements will be reviewed from the HSSE perspective and necessary measures
will be implemented.
All slings and shackles will have inspection verified and color coded before lifting works. If any
damage is noticed they will be moved from worksite.
Before erection works start, the concrete surfaces of the foundations shall be checked &
roughened by chipping. After checked by GAMA QA/QC Management and handed over
documentation, erection facilities shall begin.
Fig_1. Typical Crane in Execution

T.4.250.902 REV-B
Page 8 of 23
Doc. Title
Q A T A R
Date/Rev. No :

19.07.2008 (Rev. F)
During erection, temporary bracing and guys shall be used to maintain structural stability as
necessary.
Workers working at height (above 1.5 meter from ground) will be 100% tied off at all times
connected to a stable/fix member. Safety belt used will have a double lanyard.
Center of gravity of structural steel piece shall be calculated to prevent risks. But if the piece is
symmetrical with regard to the center line, there is no need to calculate gravity center.
Wherever possible all loads to be double wrapped.
A general cleanup of the work area will be conducted to ensure that no unused materials are
left on the erection site. All material retrieved will be sent to the warehouse for proper storage.
Detailed installations are given below.
10.1.1 STEEL STRUCTURE ON FOUNDATION OR PEDESTAL
For each block of drawings, assembly of the structural steel elements on the foundation or
the pedestal will first start from the two columns that have diagonal elements in-between.
The other structural elements will be assembled around the first assembly.
A piece (two columns with girder(s) and diagonal(s) if any) will be pre-assembled on the
ground above wooden supports, followed by the opposite piece.
Preliminary tightening of all nuts and bolts used for the pre-assembly shall be carried out
using appropriate hand tools as per ref. T-4.231.527 recommendations.
Welding processes shall be carried out on the ground as much as possible. If the welding
at height is unavoidable, necessary safety precautions will be taken for the execution.
All of the welding will be done with qualified welders who will perform actual production
welding in accordance with the appropriate welding procedures.
Erection tolerances will be as per drawings supplied by Supplier.
Four alternate methods will be used for the loosening of the slings and tightening of the
bolts. These alternate methods are briefly described below:
1. Before lifting the piece that is on the ground, a ladder and scaffold will be
assembled onto the piece for loosening slings and tightening bolts. Workers will
climb ladder by using safety belt and safety block.
2. Second way for loosening slings and tightening bolts is using a manlift.
3. The 3rd alternative is using life lines between two structural steel columns, above
1.5 meter from top of girder. Workers will climb through ladder by either using
safety belt & safety block or use manlift or safety set to reach proposed levels. After
he reaches proposed level, he will sit on the girder to loosen the slings.
4. The 4th alternative is using Man-Basket (Construction cage) manlift + Boom Truck,
etc.
10.1.2 PRE-STABILIZATION
After the pre-assembly on the ground, one piece will be erected with a crane. Stability of
the piece will be achieved via Grip hoist puller and/or crane. Each piece will be thoroughly
assembled to the foundation or the pedestals anchorage with nuts before actual crane
and/or Grip hoist puller release. This will be followed by the assembly of the two highest
column to column girders via the use of manlift(s), life lines or ladder/scaffold.
T.4.250.902 REV-B
Page 9 of 23
Doc. Title
Q A T A R
Date/Rev. No :

19.07.2008 (Rev. F)
10.1.3 FINAL STABILIZATION & COMPLETING

After the assembly of the two girders, the verticality and leveling of the four columns will
be checked. If the columns are found to not be on level and vertical, corrective action will
be performed. Assembly of the other parts of the steel structure will continue later with the
use of manlift(s), life lines or ladder/scaffold.
Tolerances in the leveling of the column bases and verticality of the columns will be set
within the allowable limits. Final bolt tightening will be made only after checking the
accuracy of the assembled frames.
10.1.4 PROCEDURE FOR USING EXPANSION ANCHOR BOLTS
Make out template for bolts holes for each column prior to drilling
Holes of 26 mm x 100 mm will be drilled in the concrete slab. Expansion anchor bolts
to be used will be M 24, stainless steel or zinc coated. For M 20 bolts, 22 mm will be
drilled
Clean-up the hole with air pressure & assume that no grit or dust are present on the
pre-drilled holes
Insert the expansion anchor bolts & slightly blow with a hammer to have an expansion
With a distance piece, screw in the nut till resistance is felt & undo the nuts
The columns are now ready to be fitted into the expansion anchor bolts
Shim plates will be provided to be able to correct the elevation of other structures
10.1.5 PROCEDURE FOR USING ADHESIVE ANCHOR & FOIL CAPSULE
Make out a template for bolt holes to be drilled
Holes of 26 mm x 100 mm will be drilled on the concrete slab for M 24 anchor rods,
22 mm will be drilled for M 20 anchor rods. Anchor rods are of stainless steel material
Clean-up the pre-drilled holes with air pressure until free of grit & dust
Insert the chemical capsule with the anchor rod drive in with rotary hammering action
Allow at least 30 minutes for curing time of the adhesive or use the table below:
Temp.
Tgel
Time
0 - 10 C
30
1 hr
10 - 20 C
20
30 min
20 >
8
20 min
After curing time the column or sub structure can be fixed
Apply for bolt torque value
11 QUALITY ASSURANCE
A Quality Assurance System shall be operated conforming to related standards. Controls and
checks shall be established and documented through relevant references: T-4.250.917 (ITP) &
T-4.250.907 (QCP).
12 HSSE
All works shall be in compliance with the State of Qatar laws and regulations, Ras Laffan
Industrial City and International standards, codes, GAMA and QSGTL requirements and
instructions.
T.4.250.902 REV-B
Page 10 of 23
Doc. Title
Q A T A R
Date/Rev. No :

19.07.2008 (Rev. F)
In addition all employees and GAMA subcontractor employees on site will have gone through
all the Site Safety Induction (Linde & Shell) and GAMA Qatar Safety induction for site safety,
health, environmental and security prior to work activities. Other training courses will be
attended as required by GAMA or QSGTL (Working at Height).
At a minimum a Risk Assessment will have been prepared by the RAT ranking the hazards
associated with project works and control measures to be taken to mitigate the hazards to an
acceptable level.
Each work scope or task will have a completed and approved JSA identifying the potential
hazards and control measures that will be implemented to protect people and environment. The
JSA will be used by Supervisor as the basis of conducting his daily TSTI meeting and his
weekly TBT.
In addition to the above, employees conducting survey works will wear required PPE and highly
visible vest where traffic or other hazards may exist. For additional safety requirements for a
particular or specific task please refer to the JSA prepared for that task.
13 ATTACHMENTS
13.1
JOB SAFETY ANALYSIS
T.4.250.902 REV-B
Page 11 of 23
Q A T A R
JSA Number: T.4.250.902
JOB SAFETY ANALYSIS FORM

NEW
Page No:
REVISED
of
12
Job being analysed: MS - STRUCTURAL STEEL ASSEMBLY WAREHOUSE, WORKSHOPS

JSA Members: Mr. Syd Osborne, Mr. Atilla Gun
Department/Section doing JSA: HSSE & Construction
Job Performers: Mr. Atilla Gun, Mr. Muslims Topaloglu
General job requirements / Common Personnal Protective
Signature
Normal Approvals:
Name
Date
Equipment.
JSA by:
Mr. Atilla Gun
17.07.08
1. The following Personal Protective Equipment shall be worn while
17.07.08 erecting structural steel at Live Area: Nomex coveralls, safety
glasses, safety helmet, safety shoes, full body harness, gloves and
Additional Approvals (Determined by Job Supervisor in correlation with LINDE HSSE Manager).
High visibility vests.
Signature
Name
Date
Job Supervisor:
Mr. Muslim Topaloglu
Discipline Superindent(LINDE)
HSSE Representative (LINDE)
OTHERS(List Below):
2.Permit To Work.
3.Intrinsically safe electrical equipment.
Approval required for hazardous work detailed in the Linde work permit procedure.
Changing conditions and emergency procedures
Stop work. Switch off equipment.Suspend lifting in a safe way. Supervisor directs personnel to nearest and safest muster point considering wind direction. Supervisor counts all
employees. Missing employees are reported to Linde HSSE Dept. When all clear is given check with Linde HSSE before returning to work.
LINDE EMERGENCY TELEPHONE NO.
HSSE MANAGER
RLIC EMERGENCY NO
583 40 72
474 88 88
Note: 1) If any of the tasks involves biological, physical or chemical hazards, then The LINDE HSSE Dept. must also approve the work.
2) Use additional sheets as necessary.
3) Details on safety (PPE,Hazard etc) and environmental requirements can be found in LINDE and QSGTL HSSE Procedures.
JOB SAFETY ANALYSIS / RISK ASSESSMENT

T.4.250.902
Q A T A R
ITEM
ACTIVITY
Transporting of
materials in the
restricted area.
HAZARD / POTENTIAL
CONSEQUENCES
1.1
Initial Risk
RISK
P C
RANK
Possible fire &

explosion.
B
1.2.
Unqualified drivers.
1.4
Struck by Vehicle
(personnel).
1.1.1
Gas test shall be conducted prior to

entry by GAMA authorized gas tester.
1.1.2
Provide a trained & competent

employee who should pave the way to
conduct Gas Test in the area of route
for truck from entering the gate to site
location.
1.2.1
A
1.3
Residual Risk
CURRENT
CONTROLS
3 LOW
Speeding.
5 MED 1.2.2
2 LOW
Strictly follow speed limit.

Current valid Qatar driving license for
the class of vehicle he is driving.
Vehicle fitted with reverse alarm, lights
and main hazard light operational, daily
check list shall be used.
All vehichle movement shall be guided
by competent banksmen.
All Materials on the truck should be
1.5.1.1
effectively secured during the
transportation.
Operator and job Supervisor shall
ensure that the vehicle is not
overloaded.
Audible reversing alarm shall be
1.6.1.1
installed on all equipment.
4 LOW
1.6
Material falling from

trucks.
Reversing and
Unloading
1.5.1
B
3 LOW
3 LOW
1.2.1.1
1.3.1
1.4.2
1.5
Drivers shall be made aware of traffic

rules and regulations.
Avoid heavy acceleration and braking.
ADDITIONAL
CONTROLS
1.2.3
1.4.1
A
SCOPE : STRUCTURAL STEEL ASSEMBLY

WAREHOUSE, WORKSHOPS
1.5.2
1.6.1
Drivers shall think ahead; drive

defensively.
MED
MED
LOW
LOW
Ensure minimum overhang of

materials outside the trailer bed.
Banksman to be provided during

Equipment Operation.

T.4.250.902
Q A T A R
ITEM
ACTIVITY
Unloading of
materials at site.
HAZARD / POTENTIAL
CONSEQUENCES
2.1
2.2
2.3
Hand & Finger injuriesBruising-Cuts while

carrying / pulling
materials.
Physical injuries back,
muscle strains, sprains
from lifting /carrying
Initial Risk
RISK
P C
RANK
3 LOW
2.1.2
2.2.1
3 LOW
Improper rigging.
2.4
Possible damage of
sling during unloading.
2.5
Slip, trip, and fall hazards
Residual Risk
CURRENT
CONTROLS
2.1.1
2.2.2
2.2.3
2.3.1
3 LOW 2.3.2
2 LOW
Dropped loads.
Ensure all employees use proper PPE

i.e. coveralls, helmet, safety glasses,
gloves and safety shoes.
One piece of material at one time
during unloading.
Ensure employee use proper lifting
techniques i.e. lift with their legs not
their back.
Use the "Buddy System" get help.
Provisions for mechanical equipment
i.e. trolley, fork lift etc..
Only certified riggers to do rigging
works.
k
Ensure all rigging gear are inspected,
color coded with Third party certified.
2.4.1
Provide softerner/padding on sharp

edges.
2.5.1
Area shall be properly maintained all

equipment and materials must be
properly stored and picked up.
Housekeeping shall be on going and
picked up at the end of the day.
Material storage areas shall be
identified and properly barricaded.
3 MED 2.5.2
2.5.3
2.6

1.1.1
1.1.2
1.1.3
4 MED 1.1.4
1.1.5
1.1.6
ADDITIONAL
CONTROLS
2.1.1.1
2.2.1.1
2.3.1.1
2.5.1.1
2.5.1.2
Third party crane inspections.

1.1.1.1
1.1.1.2
Daily crane checks.
Competent riggers.
Inspection of rigging gear & equipment.
1.1.1.3
SWL displayed.
Test reports, rigging checks.
Ensure TSTI are executed &

Implementation of safety advises
monitored.
LOW
LOW
LOW
LOW
LOW
Break the job down into

manageable portions.
Rigging work to be closely

i db
by th
the Lifti
Lifting/Rigging
/Ri i
supervised
supervisor.
Remove any unecessary materials.

Materials shall be properly
store/stack piled.
Discuss in TSTI.
Barricade swing radius of crane
and provide warning signs on the
drop zone.
Prevent anyone on the risk zone.

T.4.250.902
Q A T A R
ITEM
ACTIVITY
HAZARD / POTENTIAL
CONSEQUENCES
2.7
Initial Risk
RISK
P C
RANK
Lifting / Crane
operations / Rigging.
Residual Risk
CURRENT
CONTROLS
Ensure that crane operator is certified
by Third party, valid certificates and
driver's licenses.
2.7.2
Ensure that all lifting gear/lifting tackle is 2.7.1.2

properly inspected and color coded.
Ensure all lifts will be controlled

and supervised by a supervisor.
2.7.3
Daily crane inspections.
Ensure all lifting equipments are

inspected / approved & color coded
as per LINDE color code chart.
4 MED 2.7.4
2.7.5
2.7.8
Preparation for preassembly at ground

level.
3.1
3.1.1
Slip, trip and fall hazards.
MED
3.1.2
3.1.3
3.2
3.3
Fall of materials from

dunnage or support.
3.1.4
3.2.1
3 LOW 3.2.2
Hand injury.
C
ADDITIONAL
CONTROLS
2.7.1
2.7.6
2.7.7

2.7.1.1
2.7.1.3
Automatic safe load indicator.

Proper set up of crane ; i.e. out riggers
fully extended.
Tag lines are to be used to control
2.7.1.4
Barricade the working area with tape
2.7.1.5
plus sign boards indicating crane lifting
is in progress to prevent unauthorized
Provision of banksman at the lifting
area to keep personnel away from the
lifting operation.
Area shall be properly maintained all
3.1.1.1
Housekeeping shall be on going and
Material storage areas shall be
Materials shall be properly stack pile.
Ensure correct cribbing of dunnage.
3.2.1.1
Ensure support can withstand maximun
intended weight/load.
3.3.1
Ensure workers hand shall be away

3.3.1.1
from the connecting pieces of materials.
3.3.2
Ensure employee has appropriate hand

protection.
2 LOW
LOW
LOW
LOW
LOW
Rigger shall be 100% visible to the

crane operator & clearly relay the
information to the crane operator.
Ensure firm footing ground

Check wind velocity.
Keep the structural steel as low as

possible to the ground.
Discuss in TSTI.

T.4.250.902
Q A T A R
ITEM
ACTIVITY
Assembly of two
columns and
structural members
at ground level.
Horizontal position.
HAZARD / POTENTIAL
CONSEQUENCES
4.1
Initial Risk
RISK
P C
RANK
Residual Risk
CURRENT
CONTROLS
4.1.1
Dropped load during

assembly.
4.1.2
4.1.3
4.2
4.3
4.4
3 LOW
2 LOW
Ensure that crane operator is certified 4.1.1.1

driver's licenses.
Ensure that all lifting gear/lifting tackle is 4.1.1.2
properly inspected and color coded.
Third party inspections.

and supervised by Rigging/Lifting
supervisor.
4.2.1
Only qualified & certified riggers to do

rigging works.
Rigging work to be supervised by

supervisor.
4.2.2
Ensure all rigging gear are inspected,

color coded with Third party certified.
4.3.1
Provide softerner/padding on sharp

edges.
Ensure proper communications
between two people working at both
ends.
Ensure proper positioning of hand &
fingers while doing the job.
3 LOW
4.4.2
4.2.1.1
LOW
LOW
LOW
All equipment of slinging,hooks,

pin, shackles shall be Third party
certified.

4.1.1.3
Automatic safe load indicator.
Proper set up of crane ; i.e. out riggers
fully extended.
4.1.7 Tag lines are to be used to control
loads.
4.1.8 Crane less than 10 years old.
4.1.9 Barricade the working area with sign
boards indicating crane lifting is in
progress to prevent unauthorized entry.
4.1.10 Permit to Work.
4.4.1
B
ADDITIONAL
CONTROLS
4.1.4
4.1.5
4 MED
4.1.6
Improper rigging.
Possible damage of
sling during lifting.
Pinch point while
connecting steel
members to connecting
plates.

4.4.1.1
Ensure that proper PPE, working

gloves is being used.
4.4.1.2
Ensure bolt and nuts are hand tight

before proceeding to the next
tasks.

T.4.250.902
Q A T A R
ITEM
ACTIVITY
HAZARD / POTENTIAL
CONSEQUENCES
4.5
Initial Risk
RISK
P C
RANK
Slip, trip and fall

C
Residual Risk
CURRENT
CONTROLS
Ensure proper stack piling of materials. 4.5.1.1
Removed unnecessary materials.
4.5.2
Ensure wooden support/dunnage are

not scattered in the work area.
Bolts/nuts should be placed in the
bag/container.
their back.
Ensure materials conforms to LINDE
specifications and procedures.
procedures
Ensure ladder are inspected and color
coded.
Ensure pipe connecting to the beam are
fixed with two beam clamp.
Ensure pipe supporting the ladder will
not obstruct user in between rungs.
Discuss in TSTI.
Ensure employee has appropriate hand
protection.
their back.
Housekeeping shall be on going

and picked up at the end of the
day.
3 MED
4.6.1
Back injury due to

manual handling.
B
Installation of
temporary access
ladder beside
column.
5.1
5.1.1
B
5.2
6.1
Installation of
temporary support for
frame stability.
6.2
3 LOW 4.6.2
4.6.3
Substandard materials.
Fall of ladder when

column was erected.
2 LOW
5.1.2
5.2.1
4 MED
6.1.1
2 LOW 6.1.2
Hand injury.
Back injury due to

manual handling.
5.2.2
6.2.1
ADDITIONAL
CONTROLS
4.5.1
4.5.3
4.6

3 LOW 6.2.2
6.2.3
4.5.1.2
4.6.1.1
5.2.1.1
6.2.1.1
LOW
LOW
LOW
LOW

Ensure ladder are fixed properly

using ladder clamp.



T.4.250.902
Q A T A R
ITEM
ACTIVITY
Lifting of assembled
structural frame.
HAZARD / POTENTIAL
CONSEQUENCES
7.1
Initial Risk
RISK
P C
RANK
Dropped loads.
Residual Risk
CURRENT
CONTROLS
7.1.1
7.1.2
7.1.3
7.1.4
4 MED 7.1.5
7.1.6
7.1.7
7.1.8
7.1.9
7.2
Overturning machines
7.2.1
B
7.3
3 LOW 7.2.2
7.2.3
7.3.1
Excessive load
exceeding capacity of
cranes.
7.3.2
B
4 MED
7.3.3
7.4
Unqualified crane
drivers/operators.
7.3.4
7.4.1
B
4 MED

7.4.2
Ensure that crane operator is certified

driver's licenses.
Ensure that all lifting gear/lifting tackle is
properly inspected and color coded as
per LINDE color code chart.
Third party crane inspections.
Competent Riggers.
Tag lines are to be used to control
loads.
Barricade the working area with sign
boards indicating crane lifting is in
Ensure that no materials are on the
assembled materials.
Ensure pre lift check to be conducted
prior to lift.
Only work on level solid ground use out
riggers with adequate support pads.
Ensure all lifts will be controlled and
supervised by supervisor.
Safe Working Load displayed.
Load chart should be available in the
cab at all times.
Display of SWL, radius of working
indication.
Ensure to have automatic safe load
indicator.
Use of out riggers and/or couterweights.
Ensure to have a valid certificates for
drivers/operators.
Competence checks for
drivers/operators.
ADDITIONAL
CONTROLS
7.1.1.1
7.1.1.2
7.1.1.3
7.2.1.1
7.3.1.1
7.4.1.1
All equipment of slinging,hooks,

pin, shackles shall be Third party
certified.
Rigger shall be 100% visible &
clearly relay the information to the
crane operator.
and supervised by a Rigging/Lifting
supervisor.
LOW
LOW
LOW
LOW
Ensure the machine shall be

travelled to the most suitable
position for the job to be carried out A
before any slewing takes place.
Provision of lifting plan if there are
critical lifts.
Only drivers/operator with Qatar

license & certified operator &
trained personnel are allowed to
work on site.

T.4.250.902
Q A T A R
ITEM
ACTIVITY
HAZARD / POTENTIAL
CONSEQUENCES
7.5
Initial Risk
RISK
P C
RANK
Sub-standard cranes
B
7.6
4 MED
Residual Risk
CURRENT
CONTROLS
4 MED
Use only cranes less than 10 years old. 7.5.1.1
7.5.2
Ensure to have Third Party Inspection.
7.5.3
Ensure to have a valid certificates

checks.
Competence checks registered riggers
clearly identified.
Ensure to have a list of competent
persons maintained.
Contractor supervisor to constantly
monitor rigger performance.
Ensure to know the weight of load.
Ensure all lifting
g equipment
q p
shall be
inspected and approved by third party
and prior to use on site.
7.6.2
7.6.3
7.7
7.7.1
7.7.2
Underrated
slings/hooks/shackles.
C
7.8
4 MED
People/material struck
by swinging loads/crane
in motion.
LOW
LOW
Ensure all lifting gear brought into

the site shall be clearly identified by
means of a name plate, supplied
A
by a manufacturer,as to SWL &
serial no.
LOW
LOW
LOW
Crane shall be inspected and

approved by third party and LINDE
prior to use on respective site.
Ensure qualified/certified rigger
oversees all lifting operations.
Keep away personnel from lifting

7.8.1.1
/moving area.
Rigger and crane operator must be
7.8.1.2
certified by third party as being
competent.
Tag lines shall be attached to control
the loads.
Personnel shall not work directly below
suspended load.
Ensure that nobody on the way of

the crane.
High visibility warning signs and
barricade shall be installed.
Assign banksman to control
passerby.
Ensure to have inspection of all

equipment prior to use on site.
Ensure after inspection to generate

report specifying any repairs,
renewals which he considers are
A
necessary if the equipment is to
continue to be used with safety.
4 MED
7.9.1
B
7.7.1.1
Safe Work Load should be display.
7.8.4
Equipment failure due to
mechanical problem.
7.6.1.2
7.7.3
7.8.3
7.9
7.6.1.1
7.8.1
7.8.2
B
ADDITIONAL
CONTROLS
7.5.1
7.6.1
Improper rigging method

4 MED 7.9.2
Inspection shall be carried out by a

competent person who has detailed
knowledge of the type of machine he is
to examine.
7.9.1.1

T.4.250.902
Q A T A R
ITEM
ACTIVITY
HAZARD / POTENTIAL
CONSEQUENCES
7.10
Setting up of lifted
frames at anchor
bolts.
8.1
8.2
Severe twisting of
assembled frame
possible collapse.
Pinch point injuries
tightening of nuts to the
anchor bolts.
Muscle strain or sprain
while positioning of
frames into anchor bolts.
Initial Risk
RISK
P C
RANK
Residual Risk
CURRENT
CONTROLS
7.10.1 Ensure permanent bracings are

installed and bolt tightened.
7.10.2 Ensure center of gravity of the frame
being lifted.
8.1.1 Ensure that all hand tools are in good
condition.
3 LOW
8.1.2 Ensure qualified/ competent employee
to carry out the task.
4 MED
8.2.1
B
3 LOW 8.2.2
823
8.2.3
8.3
Bolts tightening.
9.1
Caught in between
column base plate &
foundation.
8.3.1
B
Hook-up of two
temporary support
stability concrete
blocks.
10.1
Hand injury.
B
10.3
Personnel injury from

poor body position.

their back.
ADDITIONAL
CONTROLS
7.10.1.1 Ensure two tag lines are controlling
the load.
8.1.1.1
8.2.1.1
Breakk th
B
the jjob
bd
down iinto
t manageable
bl
portions.
Only authorized & skilled worker for the 8.3.1.1
task.
Ensure workers not to hold base plate.
Ensure that all hand tools are in good

condition.
2 LOW 9.1.2 Ensure qualified/ competent employee
to carry out the task.
9.1.3 Ensure not to use cheater bar.
10.1.1 Area shall be properly maintained all
LOW
LOW
LOW
LOW
LOW
LOW
Discuss in TSTI.
Discuss in TSTI.
Discuss in daily TSTI.
9.1.1
Pinch point .
10.2
3 LOW
8.3.2
10

10.1.1.1 Remove any unecessary materials.
3 MED 10.1.2 Housekeeping shall be on going and

10.1.3 Material storage areas shall be
10.2.1 Ensure employee has appropriate hand
protection.
2 LOW
10.2.2 Discuss in TSTI.
10.3.1 Warn employees of pinch or crush
10.3.1.1 Discuss in daily TSTI.
points.
3 LOW
10.3.2 Two tag lines shall be attached to
control the loads.

T.4.250.902
Q A T A R
ITEM
11
ACTIVITY
HAZARD / POTENTIAL
CONSEQUENCES
11.1
Removal of sling
using Manlift (Option
1).
11.2
11.3
Initial Risk
RISK
P C
RANK
Improper use of Manlift.
Hand injury from

removing of sling.
Fall of personnel.
3 LOW
2 LOW
Removal of sling
using temporary
ladder (90 deg
deg.
Vertical with rope
grab).
11.4
11.5
Fall of personnel while

ascending/descending
vertical ladder.
ladder
Installation of girders 12.1

between column and
other structural
elements.
3 LOW
Fall of personnel while

transferring from ladder
to beam (vice versa).
B
12
4 MED
3 LOW
Dropped loads.
4 MED

Residual Risk
CURRENT
CONTROLS
11.1.1 Ensure that equipment operator is
certified by Third party, valid
11.1.2 Inspection sticker for the manlift.
11.2.1 Ensure employee has appropriate hand
protection.
11.3.1 All employees shall wear inspected full
body harness fitted with twin lanyards
with shock absorbers, each lanyard
shall be fitted with dual action selflocking safety hook for 100% Tie-off.
11.4.1 Ensure one lanyard is connected to the
rope grab or inertia type reel.
11 4 2 Ensure 3 points contact when using the
11.4.2
ladder.
11.5.1 Ensure spare lanyard is connected on
the lifeline before removing the other
lanyard which is connected to the rope
grab/inertia type reel.
11.5.2 Ensure firm footing on the
beams/girders before any attempt to
transfer.
12.1.1 Ensure that crane operator is certified
driver's licenses.
12.1.2 Ensure that all lifting gear/lifting tackle is
properly inspected and color coded as
per LINDE color code chart.
12.1.3 All equipment of slinging,hooks, pin,
shackles shall be Third party certified.
ADDITIONAL
CONTROLS
11.1.1.1 All vehichle movement shall be
guided by competent banksmen.
LOW
LOW
LOW
LOW
LOW
11.3.1.1 Discuss working at height in extra

TSTI.
11.4.1.1 Ensure that there are no

obstruction in between rungs of a
ladder
ladder.
11.5.1.1 Ensure to avoid haste.
12.1.1.1 Rigger shall be 100% visible &

clearly relay the information to the
crane operator..
12.1.1.2 Ensure all lifts will be controlled
and supervised by a supervisor.
12.1.4 Third party crane inspections.

12.1.5 Competent Riggers.
12.1.6 Daily crane inspections.
10

T.4.250.902
Q A T A R
ITEM
ACTIVITY
HAZARD / POTENTIAL
CONSEQUENCES
Initial Risk
RISK
P C
RANK
12.2
12.3
12.4
12.6
ADDITIONAL
CONTROLS
12.1.7 Tag lines are to be used to control

loads.
12.1.8 Barricade the working area with tape &
4 MED
sign boards indicating crane lifting is in
12.2.1.1 Ensure qualified/certified rigger

oversees all lifting operations.
12.2.1.2 Rigger shall be 100% visible to the
LOW
12.3.1
12
31 E
Ensure to
t know
k
the
th weight
i ht off load.
l d
12.3.2 Ensure all lifting equipment shall be
4 MED
inspected and approved by third party,
prior to use on site.
12.3.3 Safe Work Load should be display.
12 3 1 1 E
12.3.1.1
Ensure allll lifti
lifting gear brought
b
ht into
i t
the site shall be clearly identified by
means of a name plate, supplied
A
by a manufacturer,as to SWL &
serial no.
LOW
LOW
LOW
LOW
U d
Underrated
t d
slings/hooks/shackles.
People/material struck
by swinging loads/crane
in motion.
Tools/materials fall
hazard.
Residual Risk
CURRENT
CONTROLS
12.2.1 Competence checks registered riggers

clearly identified.
12.2.2 Ensure to have a list of competent
4 MED
persons maintained.
12.2.3 Contractor rigging supervisor to
constantly monitor rigger performance.
Improper rigging method
12.5

12.4.1 Keep away personnel from lifting

12.4.1.1 Ensure that nobody on the way of
/moving area.
the crane.
12.4.2 Rigger and crane operator must be
12.4.1.2 High visibility warning signs and
certified by third party as being
barricade shall be installed.
4 MED
competent.
12.4.3 Tag lines shall be attached to control
the loads.
12.4.4 Personnel shall not work directly below
elevated works.
12.5.1 Ensure bolts/nuts are contained in bolts 12.5.1.1 Barricade and secure the working
area with signboard.
bags.
3 LOW
12.5.2 Tools shall be tied with retaining rope
attached to the body harness.
Lifeline failure.
B
4 MED
12.6.1 Ensure lifeline has a design

calculation/Engineering design.
12.6.2 Ensure lifeline can withstand load
impact as per LINDE procedure.
12.6.1.1 Lifeline should be inspected by

scaffolding supervisor prior to its
use.
11

T.4.250.902
Q A T A R
ITEM
13
ACTIVITY
Alignment of
structural columns.
HAZARD / POTENTIAL
CONSEQUENCES
13.1
13.2
Possible fall down of

frame.
Initial Risk
RISK
P C
RANK
14
Final bolt tightening

using electric torque
wrench.
Final bolt tightening

using mechanical
torque wrench.
14.1
14.2
14.3
14.4
ADDITIONAL
CONTROLS
13.1.1 Tie-back or Provision of strong back

support to prevent frame from any
deflection and fall.
13.2.1 Area shall be properly maintained all
13.1.1.1 Work will be supervised at all times

as per Work Method Statement.
A
LOW
3 MED 13.2.2 Housekeeping shall be on going and

LOW
LOW
LOW
LOW
4 MED
Electric shock.
4 MED
1 LOW
Hand & Finger injuries.
Fall of personnel.
Slip, Trip & Fall from

same level due to
cluttered area.
Residual Risk
CURRENT
CONTROLS

3 LOW
3 MED
13.2.3 Material storage areas shall be

14.1.1 Insulate yourself from work and ground.
14.1.2 Ensure tools/equipment are of correct
type, size and they are in good
condition and inspected.
14.1.3 Ensure good electrical connection.
14.1.4 Dont allow any live electrical parts to
touch the ground.
14.2.1 Ensure employee wearing suitable
gloves when using mechanical torque
wrench.
14.2.2 Only qualified & trained employee will
carry out the task.
14.3.1 All employees shall wear inspected full
body harness fitted with twin lanyards
with shock absorbers, each lanyard
shall be fitted with dual action selflocking safety hook for 100% Tie-off.
14.4.1 Housekeeping shall be a priority, walk
and work areas shall be kept free of
materials.
13.2.1.1 Remove any unecessary materials.
14.1.1.1 Ensure all electrical equipment

were properly grounded and built
with ELCB at their source.
14.1.1.2 Dont touch electrically live parts
with skin or wet clothing.
14.3.1.1 Discuss working at height in TSTI.
14.3.1.2 Keep cables, materials, tools neatly

organised.
12

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Pearl GTL

Project Document Number: T.4.250.902

Purchase Order Number:

QATAR SHELL GTL PROJECT (PEARL)

Company Comments Incorporated

Issued for Company Comments (Included fixing of

Ready For Construction

Issued for Company Comments

Issued for Review

Issued for Internal Review

Prepared Checked Approved

METHOD STATEMENT FOR STRUCTURAL STEEL

Project Document Number: T.4.250.902

METHOD STATEMENT FOR STRUCTURAL STEEL

EQUIPMENT & MATERIAL ............................................................................................................................................ 6

MECHANICAL WORKS MANAGER

STEEL STRUCTURE SUPERINTENDENT

METHOD OF EXECUTION ............................................................................................................................................. 7

9.1.1 WORK PERMIT

9.1.2 TRAFFIC MANAGEMENT PLAN

9.1.3 HANDLING, STORAGE AND PRESERVATION

9.1.4 EQUIPMENT AND PERSONNEL

10 PREASSEMBLY & ERECTION ..................................................................................................................................... 7

10.1.3FINAL STABILIZATION & COMPLETING

10.1.4PROCEDURE FOR USING EXPANSION ANCHOR BOLTS

10.1.5PROCEDURE FOR USING ADHESIVE ANCHOR & FOIL CAPSULE

11 QUALITY ASSURANCE ............................................................................................................................................... 10

METHOD STATEMENT FOR STRUCTURAL STEEL

METHOD STATEMENT FOR STRUCTURAL STEEL

QSGTL or its PMC

5 EQUIPMENT & MATERIAL

Mobile crane 60 Ton

Fabricated structural steel members

METHOD STATEMENT FOR STRUCTURAL STEEL

8.2 STEEL STRUCTURE SUPERINTENDENT

9.1.1 WORK PERMIT

10 PREASSEMBLY & ERECTION

METHOD STATEMENT FOR STRUCTURAL STEEL

Fig_1. Typical Crane in Execution

METHOD STATEMENT FOR STRUCTURAL STEEL

METHOD STATEMENT FOR STRUCTURAL STEEL

10.1.3 FINAL STABILIZATION & COMPLETING

METHOD STATEMENT FOR STRUCTURAL STEEL

JOB SAFETY ANALYSIS

JOB SAFETY ANALYSIS FORM

Job being analysed: MS - STRUCTURAL STEEL ASSEMBLY WAREHOUSE, WORKSHOPS

Mr. Muslim Topaloglu

JOB SAFETY ANALYSIS / RISK ASSESSMENT

Possible fire &

Gas test shall be conducted prior to

Provide a trained & competent

Strictly follow speed limit.

Material falling from

Drivers shall be made aware of traffic

SCOPE : STRUCTURAL STEEL ASSEMBLY

Drivers shall think ahead; drive

Ensure minimum overhang of

Banksman to be provided during

JOB SAFETY ANALYSIS / RISK ASSESSMENT

Hand & Finger injuriesBruising-Cuts while

Slip, trip, and fall hazards

Ensure all employees use proper PPE