Erection Method Statement Royal Comision (Hollow Core)

METHOD STATEMENT FOR ERECTION OF

PRECAST ELEMENTS

File No. : EPC- 003

Ref. No. : EPC/SD/RAE-03

Rev. : 0

Date : 08/04/2013

EASTERN PRECAST CONCRETE

ERECTION PROCEDURE FOR CONCRETE PRECAST HOLLOW CORE

Revision Record

RevNo. Date Prepared by Reviewed By: Approved By: Remarks

2 08/04/2013 Engr. Alfred Comendador

Engr. Muzamil Salih Engr. Luai

Shammat

QA/QC Dept.Supervisor Erection Manager General Manager

CLIENT:

OWNER:

CONTRACTOR:

METHOD STATEMENT FOR ERECTION OF

PRECAST ELEMENTS

File No. : EPC- 003

Ref. No. : EPC/SD/RAE-03

Rev. : 0

Date : 08/04/2013

1.0 Purpose

To introduce the methodology for erection of hollow core slab precast elements.

2.0 Scope

Design, production, delivery and erection for the following precast elements:- Hollow core slabs

3.0 Personnel Responsible

3.1 Erection Manager: Overall in-charge for the project execution.3.2 Erection Engineer: Over-all in-charge for the erection processes. Ensure that the

erection is done with accordance to the standard safe erection practices. Prepare delivery schedule program.

3.3 Erection Foreman: Responsible for overall erection at site. Coordinate with the main contractor with regards to the access for trailer and crane. The erection foreman is available at site during erection.

4.0 Responsibility

4.1 Competent workers are to be provided, who are properly and well train to load, deliver and erect all types of precast elements which required to achieved completely satisfactory project.

4.2 The main contractor is responsible for providing proper access for the loaded trailers to the position in the erection site premises.

4.3 Eastern Precast will provide all necessary erection accessories to complete the erection works.

5.0 Preparation before the erection

5.1 Prior to commencing the handling and erection of precast concrete elements, the following items should be considered by Site Contractor and EPC.

5.1.1 Check the crane and trailer access in the site and ensure that it is leveled and compacted.

5.1.2 Ensure that the dowels embedded in the foundation is in the right place or location

5.1.3 Clear the site for truck and crane access ensuring room for crane outriggers, counterweight tail swing, boomswing and under hook and overhead obstructions.

5.1.4 Ensure that sufficient space is available for precast propping or bracing.

CLIENT:

OWNER:

CONTRACTOR:

METHOD STATEMENT FOR ERECTION OF

PRECAST ELEMENTS

File No. : EPC- 003

Ref. No. : EPC/SD/RAE-03

Rev. : 0

Date : 08/04/2013

6.0 Procedures for the Erection of Precast elements

6.1 Erection of Hollow-core slabs

6.1.1 Hollow core slabs are transported to site on flatbed trailers. 6.1.2 Before erection of any slabs, the supporting structure should be checked to

determine if all pertinent dimensions correspond with those shown on the approved drawings.

6.1.3 Prior to placing slabs the bearing surfaces should be checked to ensure that they are smooth and level.

6.1.4 Leveling material should be placed if required. 6.1.5 The trailer carrying the hollow core slabs is brought close to the building, under

reachable crane radius where erection is to be carried out. 6.1.6 Precast HCS will be delivered at site with open cores, cores will be closed with

polystyrene core plugs or plastic end caps by main contractor either before lifting the HCS form the trailer or after erection prior to place welded mess and prior for casting/screeding to avoid concrete flow inside the core while casting.

6.1.7 Precast HCS will be lifted directly from the trailer by using lifting scissor or lifting belt and place in proper location one by one, if the component lifted for at least 1 meter from the ground or from the trailer, safety chains underneath the HCS should be placed and clamp it with lifting scissor and it should not be released until the HCS is about 1.00 m from the support for safety reason.

6.1.8 Lifting area surrounding the trailer should be cordoned and barricaded by warning tape with a safety signboards precaution.

CLIENT:

OWNER:

CONTRACTOR:

METHOD STATEMENT FOR ERECTION OF

PRECAST ELEMENTS

File No. : EPC- 003

Ref. No. : EPC/SD/RAE-03

Rev. : 0

Date : 08/04/2013

6.1.9 Controlling the movement of precast HCS by using taglines (rope) to its final location.

6.1.10 Upon completion of the erection of HCS, soffit of HCS will be check and corrections will be carried out wherever necessary.

6.1.11 Final inspection form for erected HCS will be raised by EPC Engineer and after the checking of HCS and approval by main contractor or consultant, welded mesh to be place and MEP provision to fixed in proper location by main contractor before screeding.

CLIENT:

OWNER:

CONTRACTOR:

METHOD STATEMENT FOR ERECTION OF

PRECAST ELEMENTS

File No. : EPC- 003

Ref. No. : EPC/SD/RAE-03

Rev. : 0

Date : 08/04/2013

6.1.12 Main contractor will cast the slab (screeding) and it will be cured 3 days at least before starting the erection precast panel for succeeding level with same procedure or methodology.

6.1.13 Care must be taken to ensure that each slab has at least the minimum bearing shown on the drawing.

6.1.14 The screeding / topping for the slabs are done according to the design.

CLIENT:

OWNER:

CONTRACTOR:

METHOD STATEMENT FOR ERECTION OF

PRECAST ELEMENTS

File No. : EPC- 003

Ref. No. : EPC/SD/RAE-03

Rev. : 0

Date : 08/04/2013

SAFETY REQUIREMENTS

Personal safety:

> Areas where overhead work is going will be treated as “hard-hat areas”. These areas should be marked with safety signs. All personnel’s working there should wear hard-hat (helmet) as protection against falling objects.

> All personnel working at site must wear safety shoes with metal toecap to protect against sharp objects. Rubber boots should be worn where work place is dirty or wet.

> Personnel handling objects with sharp edges are required to wear hand gloves. Personnel in loading and unloading section must wear gloves while at work.

> Personnel handling grinding machines and power saws are required to wear safety glasses to protect eyes from flying dust.

> The persons working at height should wear safety harness.

> Respiratory masks should be worn while spray painting, sand blasting, working with cement & silica and during work which generates fine dust.

> All persons should follow the safety rules set forward by the main contractor.

Cranes & Other lifting gear

> The responsibility for maintaining the hired cranes is with the agencies. However it is the responsibility of the site supervisor to ensure all hired cranes are tested / inspected as per the statutory requirements and are having the valid certificate.

> For EPC owned cranes, supervisor shall ensure that the crane is maintained as per the statutory requirements.

> Crane should be selected based on the load to be carried, height of the building and distance of the crane fixing from the building.

CLIENT:

OWNER:

CONTRACTOR:

METHOD STATEMENT FOR ERECTION OF

PRECAST ELEMENTS

File No. : EPC- 003

Ref. No. : EPC/SD/RAE-03

Rev. : 0

Date : 08/04/2013

> Crane should be positioned and fixed correctly such a way that it should not move from its place during use. Area around the crane should be clear for free movement of the crane boom so that no obstacle or hindrance is encountered while transporting the panel from trailer to the spot.

> Ensure ground conditions are good enough to receive delivery vehicles. Use a spotter to direct the trucks and cranes.

> Slings and ropes that have marked safe working load should be used.

> When synthetic belts are used, sharp corners should be padded, as there is a chance for the belt to get cut.

> Do not put hands or fingers between the slings and its load while the sling is being tightened around the load.

> Ensure that shackle pins are screwed home.

> Safety hooks will be fitted with latches to prevent displacement of load.

> Ensure that edges of nylon belts and ropes are not damaged.

> All lifting equipments should have valid test certificates.

> Do not use a damaged or defective sling.

> Do not shorten a sling with knots, bolts or other makeshift devices.

> Do not load a sling from the sharp edges of its load.

> Sharp corners of the load should be padded to prevent damage to the product and sling.

> Shock loading should be avoided.

> Do not pull a sling when load is resting on it.

> Immediately remove a damaged or defective sling from service and destroy it to prevent further use.

The following safety precautions should be followed during lifting & rigging

> Personnel used for signaling i.e. riggers, should be properly trained.

CLIENT:

OWNER:

CONTRACTOR:

METHOD STATEMENT FOR ERECTION OF

PRECAST ELEMENTS

File No. : EPC- 003

Ref. No. : EPC/SD/RAE-03

Rev. : 0

Date : 08/04/2013

> Crane operator should have a clear view of the signaller.

> If loading and unloading is at two different points then different signaler should be used at each location.

> No one is allowed to ride the load, crane hook.

> Position the boom at the highest possible boom angle, travel at slow speed and keep the load as close as practical to the ground, avoid sudden stops and starts.

> Before releasing the panels ensure that it is in proper position, has proper bearing and is stable.

> Check to ensure that necessary or temporary connections have been done.

The following things should be checked before performing any lifting operation.

> The lifting shackle should be free of any defect or damage. If any damage is found it must be reported and corrected before the operation.

> The operator must have a good idea of the following things before lifting

- Weight of load to be lifted- Load size & centre of gravity- Height to be lifted & final position of the load- Maximum radius at which load can be lifted- Restriction caused by plants, buildings, power lines etc.- The ground condition- The swing radius of the crane

> Only trained and licensed persons are authorized to operate cranes.

> Under no circumstances the crane shall be operated beyond its safe working load.

> All safety devices fitted must be in good working condition.

> All lifting machines, chains, ropes & lifting tackles etc. that has been altered shall be adequately retested by a competent person / authority.

> Make sure the load does not exceed the rated capacity.

> There should not be any loose items on the load or the crane before lifting.

CLIENT:

OWNER:

CONTRACTOR:

METHOD STATEMENT FOR ERECTION OF

PRECAST ELEMENTS

File No. : EPC- 003

Ref. No. : EPC/SD/RAE-03

Rev. : 0

Date : 08/04/2013

> Hoist line must be vertical prior to the lift.

While moving the load:> Do not pass the load over the workers.> Do not leave suspended loads unattended.> Do not attempt lifts beyond the rated load capacity of a crane or sling.

Inspection

Before each day’s use and at shift changes, the crane operator is responsible for visually inspecting the crane to ensure that all operating and safety functions are working correctly. The erection foreman shall ensure that these checks have been carried out.

The operator must visually inspect ropes before each day use. This inspection is done by running the block to its lowest point, then slowly running it back up observing all parts of the cable for signs of damage, including

- Severe twists- Broken wires- Deformed, worn, or flattened wires and;- Corroded or pitted surfaces

Ensure that the fiber slings used for lifting HCS are inspected for any damage by removing their protection covers before any lifting is being done.

Annual Inspection

Each crane must have its loading and boom hoists fully inspected at least once a year in order to ensure the integrity of the wire rope and the maintenance supervisor should maintain a record of the same.

WORKING AT HIGH ELEVATION

Scaffolds / Ladders / Guard Rails / Mid Rails / Toe Board

> Scaffolding and working platforms used for working should be properly secured.

> Don’t overload the scaffolding or working platforms.

> If scaffolding is provided by the main contractor, then it must be inspected in advance to ensure that it meets the requirement.

CLIENT:

OWNER:

CONTRACTOR:

METHOD STATEMENT FOR ERECTION OF

PRECAST ELEMENTS

File No. : EPC- 003

Ref. No. : EPC/SD/RAE-03

Rev. : 0

Date : 08/04/2013

> Do not alter a scaffold once it has been certified fit to use.

> All scaffold erectors shall wear a full body harness with double lanyard and must be 100% tied off to an anchorage point.

> When using a ladder to get to an elevated surface extend the ladder 3 rungs (36 in) past the bearing point to provide a handhold for getting on & off. Ladder will be safe tied offv and have protection against falls of men and materials.

> Set the base of a straight or extension ladder back a safe distance from the vertical approximately one-fourth the working height of the ladder to ensure stability.

> Do not use broken or damage ladders.

> Always secure straight or extension ladders at the top.

> In addition to the above all standard safety precautions related to scaffolding has to be followed.

Guard rails, mid rails and toe boards will be fitted at edges of decking to prevent men from falling off. Guard rails will be 106 cm in height and toe boards not less than 15cm in height. Both will be securely fixed.

The following safety precaution shall be followed while working under windy conditions

> Extra caution should be taken while erection of hollow core slabs & panels under windy conditions. High-speed winds cause swinging of the precast elements when lifted with the crane. Under these conditions there is danger that the elements may swing excessively and hit the nearby persons or building. Taglines used in these conditions may not help.

> When the wind speed is more than 20 knots stop erection of precast components.

> Stop erection when it is unsafe to work.

The following safety precaution shall be followed while working around live electric lines.

> While erecting precast components in the vicinity of high power electric lines, utmost care is required. Any direct contact with the live power lines may lead to fatal accidents.

> Work in the vicinity of electrical power lines is to be done under two conditions.. By disconnecting the power connection. Under charged lines

By disconnecting power linesCLIENT:

OWNER:

CONTRACTOR:

METHOD STATEMENT FOR ERECTION OF

PRECAST ELEMENTS

File No. : EPC- 003

Ref. No. : EPC/SD/RAE-03

Rev. : 0

Date : 08/04/2013

> If the power lines are to be disconnected, then ensure electrical authorities are informed in advance. Make an arrangement with the electricity authority not to reconnect the power unless it is confirmed.

> Start crane operation only after ensuring that electricity is disconnected.

Working under charged lines

> If work is to be carried out under charged electrical lines, then minimum distances are to be maintained between the nearest electrical line and any part of the crane or load.

CLIENT:

OWNER:

CONTRACTOR:

Voltage ratings of power lines Minimum required clearance

while working

(kV) (m)

Up to 44 3

44 to 220 5

220 to 440 7

440 to 660 10

660 to 1100 14

METHOD STATEMENT FOR ERECTION OF

PRECAST ELEMENTS

File No. : EPC- 003

Ref. No. : EPC/SD/RAE-03

Rev. : 0

Date : 08/04/2013

> Maintain a minimum gap of 5 m between the nearest electrical line and any part of the crane or load if electrical ratings are not known provided you are not working in a domestic area. In other cases, contact your supervisor.

Calculations for the use of 16mm dia. cables as a LIFELINE

RC REQUIREMENT :

1. Under the subject “ Fall Arrest & Work Restraint Systems, Nets & Rope Access” , Standard No. 218 dated May 30 2009.

2. Lifeline Systems : are points of attachment for the safety harness larnyard and must be capable of supporting 5000 lbs (2268kgs) per employee. Lifelines may be mounted either horizontally or vertically and are generally intended to provide mobility to personnel.

COMPLIANCE :

16 mm dia. Wire Rope (Cable) shall be used as a Lifeline for Erecting Hollow Core Slab.

16mm = 5/8” ; ( Recommended safe working load of a 5/8” wire rope life line is 6,650 lbs. or 3,022 kgs.)

Hence, 16mm dia. Lifeline can support the RC requirement of 5000 lbs (2268kgs) per person.

Life line shall be attached at both ends with a pipe 1.2 meters away from the edge of the building.

The length of the lifeline varies depending on the area where hollowcore slab or pre-cast panels erection is being performed. Under normal circumstances, column to columns distances is the precise location of the tie in points of the lifeline.

CLIENT:

OWNER:

CONTRACTOR:

METHOD STATEMENT FOR ERECTION OF

PRECAST ELEMENTS

File No. : EPC- 003

Ref. No. : EPC/SD/RAE-03

Rev. : 0

Date : 08/04/2013

To ensure that the rope will not slide, three (3) clips will be going to hold wire rope at each end of the line.

It shall be ensured that all life line are so connected that 100 % tied off is maintained at all time while moving on the working area.

7.0 HEALTH AND SAFETY

7.1. RISK ASSESMENT AND SAFETY MEASURES

Hazard Risks Control MeasuresPlant and Machinery Injury to personnel /

Damage to propertyAll plant and machinery to be inspected and serviced regularly as per ISO 9001:2008 QMS and KSA Regulations

A maintenance and service schedule is to be established and implemented.

Failure of lifting equipment

Damage to buildings/equipment and injury/death to personnel

All lifting equipment is to certificated and inspected regularly

A copy of certification is to be retained on site for record keeping and reference.

Slinger / Signaller to carry out visual inspection prior to use

CLIENT:

OWNER:

CONTRACTOR:

METHOD STATEMENT FOR ERECTION OF

PRECAST ELEMENTS

File No. : EPC- 003

Ref. No. : EPC/SD/RAE-03

Rev. : 0

Date : 08/04/2013

Falling Materials Damage to buildings/equipment and injury/death to personnel

All lifts are to be carried out by competent trained slinger/signallers

All lifts are to be carried out as directed in the lifting assessments and schedule of common lifts

Free falling loads Damage to buildings/equipment and injury/death to personnel

Daily inspections and checks are to be made by the crane operator to ensure that the crane is safe and operable

Heavy loads Failure of lifting equipment and machinery / Damage to equipment and injury to personnel

Visual assessments are to be made by competent personnel to ensure the correct lifting equipment is used for the lift and that the crane is able to lift the weight of the load at the required radius

All lifts are to be carried out as directed in the lifting assessments and schedule of common lifts

High Winds Instability and loss of control of lifting operation / Damage to equipment

Wind speeds within the site area are to be monitored and all lifting operations are to be in strict conditions of the wind speed allowances as laid down for the restrictions of safe use of cranes in high wind and wind conditions.

CLIENT:

OWNER:

CONTRACTOR:

METHOD STATEMENT FOR ERECTION OF

PRECAST ELEMENTS

File No. : EPC- 003

Ref. No. : EPC/SD/RAE-03

Rev. : 0

Date : 08/04/2013

Unscheduled / Non competent lifts

Damage to buildings/equipment and injury/death to personnel

No unauthorised persons are to carry out any lifting operations, all operatives are to show proof of their competency prior to employment.

A lifting assessment is to be carried out prior to any unique or special lifts being carried out.

Close proximity of cranes/building/public amenities

Entanglement leading to loss of integrity of load / Damage to Equipment / Injury to Personnel

A safe system of work is to be instigated ensuring the risk of collision is eradicated.

Environmental Safety & Health Contractor Requirements● Personal Protective Equipment

Protective & Safety Equipment ● The following are the list of Personal Protective Equipment:

1. Hard hat 2. Safety shoes 3. Dust Mask 4. Safety goggles 5. Rubber gloves 6. Safety Vest 7. Safety built Ladder

CLIENT:

OWNER:

CONTRACTOR:

REF. # : EPC-LP-01

DATE : Organization Name: Eastern Precast Concrete Date of LiftProject Name # Work Permit Required Yes NoFacility Name Specific Work Location Contract #A. Load Description & Weight ( From User ) B. Load Handling DevicesPrecast hollowcore slab Load Handling / Boom Erected N/A Weight

Lbs./Kgs.C. Crane Information Attachments:1. Inspection Sticker Yes √ No Swing Away Jib2. Inspection Sticker Expiry Date March 19,2013 Othe Jib3. Equipment ID # Hook Block ( Main ) 750 Kgs.4. Crane Model Auxilliary Boom Head5. Crane Type Mobile crane Headache Ball6. Crane rated Capacity Lifting/ Spreader Beam Needed: Yes__No__7. Crane Operating Code # Does beam Have inspection sticker? Yes__No __ N/A8. Single Line Pull Capacity Sling, Shackles etc.9. No. Of Part Of Line Others10. Total Gross Capacity Hook Block Weight of Load Handling Devices ( Section B )

(+) Weight of Load to be Lifted ( Section A )(=) Total Gross Weight

D. Crane Configuration E.Rigging1. Required Boom Length 1. Hitch arrangement2. Boom Angle 2. Sling Type/s3. Required Counter Weight 3. Sling Size/s4. Operating Radius 4. Sling Length/s5. Lift Quadrant ( Front, Rear, 360 degree ) 5. Hook size: 22.0 mm.

degree 6. Capacity of above configuration: Crane Capacity in this configuration (if applicable): 31.8 kgs. Lbs/kgs Total Gross Weight/Capacity= Surface requirements Needed (other than mandatory outrigger pads): Mats? Yes___ No √Is the ground level? Yes___ No √ : Is ground compacted? Yes √ No____ Excavation hazards controlled? Yes √ No___: Others_________________ Yes____ No___Wind speeed shall not exceed GI 7.027 Limits for Manbaskets: Wind Speed:_______Mph (max. 20 Mph )Energized Power lines Within Boom Radius? Yes___ No √Explosive/Fire/High heat hazards within boom radius? Yes___ No √Is this a night time crane lift? Yes___ No √If yes do you have written approval from the facility manager? Yes ___ No___

Contractor:Reviewed By:

Erection Enginner/Supervisor: Eng'r Khalid Muzamil

Certified Rigger: Nandlal ____________________________Certificate #: ___________________________________ Site Representative

Approved By:Crane operator: Ram Chetri ________________________Certificate # : C-12122210Comments :

LIFTING PLAN

CRITICAL LIFTING PLAN

INFORMATION ABOUT THE CRANE LIFT TO BE ATTACHED TO THIS PLAN

METHOD STATEMENT FOR ERECTION OF

PRECAST ELEMENTS

File No. : EPC- 003

Ref. No. : EPC/SD/RAE-03

Rev. : 0

Date : 08/04/2013

Contractual Requirements● Personal Protective Equipment shall be considered only as “last resort of defense” against potential risk and hazards.

● Contractor shall ensure that adequate stock of Personal Protective Equipment are readily either available on site or issued to personnel. PPE shall be considered as consumable items.

● All PPE utilized shall be manufactured to a recognized international acceptable standard.

CLIENT:

OWNER:

CONTRACTOR: