Document#:JS19-010-MOS-FAB

R 001
METHODSTATEMENT FOR
FABRICATION STEEL STRUCTURE

Steel Structure for Tareq -Ain Ghazal

Link (BRT) Phase 1 - Project

METHODSTATEMENT FOR
FABRICATION STEEL STRUCTURE

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METHODSTATEMENT FOR
FABRICATION STEEL STRUCTURE
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Contents

1. PURPOSE .............................................................................................................................................. 3
2. SCOPE OF WORK................................................................................................................................3
3. REFERENCES ....................................................................................................................................... 3
4. DEFINITION…......................................................................................................................................3
5. ABBREVIATIONS.................................................................................................................................3
6. RESPONSIBILITES .................................................................................................................................4-6
7. MATERIALS………………………………………………………………………………………..….6
8. WORK METHODOLOGY ..................................................................................................................6-10
9. MACHINERY AND EQIUPMENTS ................................................................................................13
10. PERMITS AND LICENSES REQUIRED…………………………………………………………...13
11. INSPECTION AND TEST REQUIREMENTS/ QUALITY CONTROL.........................................13
12. HEALTH, SAFETY & ENVIRONMENTAL……….........................................................................14
13. EMERGENCY ARRANGEMENTS ...................................................................................................14
14. REFERENCES DOCUMENTATION………………………………………………………………..15
15. CONTRACT DOCUMENTATION................................................................................................... 15

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METHODSTATEMENT FOR
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1. PURPOSE

The purpose of this method statement is to establish the safe working methodology for QAIA Rehabilitation,
Expansion and Operation Agreement BHS Extension and Upgrading of HBS project and ensure that all works
are carried out in accordance with the approved shop drawings, welding specification, standards and project
specification.
The Manufacturer reserves his right to adapt the methods of execution as contained in this document from
time to time, according to specific working conditions at factory, in agreement with the Engineer.

2. SCOPE OF WORKS

This method statement describes/covers all the activities undertaken through the whole fabrication process,
which is considered the main process in the company.
The Web Cope Crack Prevention Starts from cutting to finish Product.

3. REFERENCES

This method statement is subject to the requirements as stated in the following regulatory & statutory
documents, applicable standards / specifications / building codes:
 Related Inspection & Test Plan (JS19-010-ITP-FAB-Rev.00)
 ISO 9001:2014: Quality managements System Requirements
 ASME IX
 AWS D1.1
 EN 10025-2

4. DEFINTIONS

a) GM : General Manager
b) OM : Operations Manager
c) PM : Project Manager
d) SE : Site Engineer
e) QA/QC : Quality Assurance / Quality Control Engineer
f) HSE : Health Safety & Environmental Engineer / Officer

5. ABBREVIATIONS

a) PD – Project Director
b) PM- Project Manager
c) CM - Construction Manager
d) QSHEM -Quality, Safety, Health, Environment Manager
e) QCM - Quality Control Manager

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METHODSTATEMENT FOR
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f) QAC- Quality Assurance & Control Engineer
g) QCI - Quality Control Inspector
h) PE – Production Engineer
i) SE - Site Engineer
j) SUR – Surveyor
k) ITP - Inspection and Test Plan
l) PTW - Permit to Work
m) ENGINEER –Supervisory Consultant
n) QCI- QC Inspector
o) NDT- Non Destructive Testing
p) WPS - Welding Procedure Specification
q) PQR – Procedure Qualification Record
r) WPQ- Welders Performance Qualification
s) FCAW- Flux Core Arc Welding
t) GMAW- Gas Metal Arc Welding
u) MTC – Mill Test Certificate

6. RESPONSIBILITIES

6.1 Manufacturer

• Head of Production is responsible for implementing, maintaining and updating of this procedure, he is considered the
process owner and he will report to the Operation Manager.
• Production Engineers are responsible for ensuring that all fabrication activities are being done in accordance with
customer requirements, they will report to the Head of Production.
• Quality Manager is responsible for all quality control related activities mentioned in this procedure, he may delegate
this responsibility to the QC Engineer.

6.2 QSHE Manager

• The QSHE Manager is responsible to ensure that all the operational documents and procedures are approved and
available at factory.
• He shall provide necessary information pertaining to inspection/ testing to Construction team and Quality team, and
shall ensure that all requirements are effectively implemented.
• He is responsible for follow up of the assigned tasks to the Quality team and working closely with related Engineering
and fabrication team for compliance with project requirements.
• to ensure that all safety precautions and procedures are in place.
• He may conduct audits or inspections to ensure said compliance.

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6.3 QA/QC Engineer

• The QA/QC Engineer is responsible to ensure work has been executed on field as per the specification, shop drawings
and approved method statement.

6.4 Safety and Health Officer

• The Safety and Health officer is responsible for monitoring and ensuring that all safety precautions are being followed
by the respective engineers, supervisory staff, In addition ensure that the supervisory staff have confirmed checked that
all personnel have undergone any necessary induction trainings and that all personnel are equipped with (PPE) Personal
Protective Equipment.
• The Safety officer shall ensure that all works have undergone the necessary pre commencement START talk provided
by the works supervisor.
• The Safety officer shall periodically inspect all works ensuring adequate signage and permits are in place.
• The Safety officer shall conduct inspections as and where necessary to ensure plant equipment is in full compliance with
the projects requirements. Where deemed appropriate issue corrective action notices and or observation reports in line
with BOTC procedures.

6.5 First Aider

• The First Aider ensures first aid kits are provisioned and are adequately available.
• He communicates with Emergency Medical Services when necessary, reassures bystanders, and ensures the wellbeing
of work colleagues, undertakes record keeping and recording.

Fire Warden

• The First Warden takes immediate action as per his training to fight the fire, evacuates the personnel, and uses the
firefighting system.

Quality Inspection
 A well-qualified Quality inspector will be stationed in the factory to perform the inspection for fabrication activities
as per the approved ITP (JS19-010-ITP-FAB-Rev00).
 He verifies/review all the documents drawings, WPS, PQR and all other qualification records and reports to his
satisfaction and project requirement.
 Performing testing & inspection as per the approved ITP (JS19-010-ITP-FAB-Rev00) frequency and as per standards
in acceptance criteria to the satisfaction.
 Final report will be submitted by this Quality inspector for complete fabrication activity signed & stamped for
Engineers satisfaction.
 Review of Material Test Certificates and associated documents.
 Review Material traceability records.

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 Review of WPS, PQR and Welders Qualification records
 Review of NDT Procedures.
 Witnessing and Review of NDT tests and final visual inspection.
 Review of Welding records and NDT reports.
 Witnessing and Review of tests for Blasting and Painting as per Specification.
 Attending meeting with Client as when required.
 Submission of reports.
 Identification and reporting of NCR and CAR and close out with effective implementation of corrective action and
preventive action.

7. MATERIALS

* Steel Raw Materials (per project specification, approved drawings & Material Submittals which will include MTC’
as per AWS D1.1 2015, (to be Submitted)
* Weld rod
* Magnetic particles
* Die penetrate
* welding rolls (SAW,FCAW & GMAW)
* Welding stick (SMAW)

8. WORK METHODOLOGY
The responsible Production Engineer shall receive materials issued from the stores for preparation, specific to this project.
All the steel materials used in this project will have a Mill test Certificate which will be submitted as per AWS D1.1 2015
with traceability records review and approved by Quality Inspection

 Welding consumables quality check added. In order to verify the welding rod grade same as per drawings yield
strength should be 420 N/mm2 to be tested.
 Verify once informed by store keeper, that batch/lot no of received welding materials conform to batch / lot
certificates.
 Review batch / lot test certificates and ensure all included test results & data which has to match steel grade.
 Sign off on the receiving inspection report and inform store keeper for storing or segregation.
 PE shall prepare nesting plans for cutting plate material and rolled steel sections. The nesting plans will be issued
to the Machine Operators through the Foreman.
 The Sequence of preparation is as follows:
 Marking.
 Cutting.

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 Rolling / forming.
 Drilling
 Issue to the responsible PE for commencement of assembly
 Bending, Bending is performed according to: -

Assembly
 Prepared items shall be assembled in accordance with drawings of the correct revision status.
 Assembly will be carried out by fitters and qualified tack welders under the supervision of a Foreman
who will report to the PE.
 In case of queries, PE will raise a Technical Query to the Engineering office will return it back with
recommended action.
 QCI will be informed by a copy of the Technical Query so that he can take any changes from the drawings
into consideration during inspection.
 QCI will check the assembly after the PE allow commencement of welding.
 All the fit up, tack welds etc will be done with 100% accuracy as per the shop drawings, welding works
carried as per WPS and as per AWS D1.1 section 16 part 5.5.

Web Cope Beam Cutting

 All the Cutting works are followed as per ASTM standards and as per AWS D1.1 2015 section16 part 4.4
whichever is applicable.
 Beam Coping shall be carried out by Oxy-fuel (Oxy-acetylene) cutting suitably either by free hand or by
machine. Notch Burning Procedure shall be as follows.

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 Gas cutting surface shall be Ground to sound metal, to remove slag and roughness.
 Radius of the cope area and adjacent flats shall be ground at least 1mm depth in order to remove HAZ area
created by the flame cut operation.
 Surface roughness of coped beam webs shall be 100% inspected visually by QC.
 Cutting Profile shall be checked for free of cracks and notches 100% visually accepted coped beams radius
and attached flat areas.
 Items above are covered in the fabrication final inspection and the findings should be included in the
Inspection Report.

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 Materials passed by visual inspection shall be released for Painting / Galvanizing.

Welding
 Welding shall be performed by suitably qualified welders working in accordance with approved WPS
(NEGEMCO-REC-W001).
 Any Welder who is not recorded in the Qualified Welders List and/or is not carrying a Welder ID card will
not be permitted to do any welding activities. Weld process will be controlled by QCI. Completed welds will
be checked visually by QCI and, where required by contract, subjected to appropriate NDE by qualified NDE
personnel
 After finishing welding the PE is to monitor the workers doing all the QCI notes and finishing all the cleaning
works.

Built-Up Sections:

 Cut the flanges & webs from plates using Plasma CNC machine based on required dimension with accuracy
up to 99.9%.
 The web will be cut from one piece (including the castellated openings and End connection joints).
 During the cutting of web, the plasma CNC machine perform groove cutting on the required groove angel
based on the sample that passed the Ultrasonic test & macro-etching test.
 Start assembly the built up sections from the two flanges & web on the (Submerged arc welding machine)
built up machine. As per below details:

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 Apply preheat if required by applicable construction code (AWS D1.1 2015) based on the thickness of thicker
plate (flange).
 Start (SAW) welding to fill the groove from both sides using the electrical parameters that used in the test
sample to control the weld deposited & minimize the heat distortion if any.

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 Inspection:
Perform visual inspection by QCI (ASNT level II)
Check dimension and the geometry of built- up section By QCI
Perform spot Penetrant test (PT) or Magnetic Test (MT) by QCI (ASNT level II)
Perform spot Ultrasonic testing to each built-up item by QCI (ASNT level II)

Final Inspection
 The PE shall inform the Quality INSPECTION of the items ready for final inspection by use of the Final
Inspection Request. All items submitted by PE for final inspection are to:
 Have visual acceptance of welds by QCI.
 NDT will be carried out by Quality Inspections per approved ITP (JS19-010-ITP-FAB-Rev00).
 Have acceptance by NDT personnel of NDT performed.
 Have tack welds of assembly aids removed by grinding.
 Be free of welding slag, excessive rust, etc.
 Be in accordance with approved drawings and Technical Queries (if applicable).
 After final acceptance by Quality INSPECTION and, if required, Client a Release Note showing
destination to where the items are released and containing accepted items will be raised.
 The fabricated product is to be transported to the destination mentioned in the release note.

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Flow Chart

Document
Chart Action
In/out Name

Document In Drawings
Controller In WPS

PE

QCI

PE

QCI/INT

Qualified
Welders

QCI

QCI

NDT
Out NDT Report
Examiner

PE

Request for
PE Out Final
Inspection

QCI/INT

Dispatch

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9. MACHINERY AND EQUIPMENTS

9.1 Equipment:
The following plant and equipment and material shall be used for the works:
* Welding machine
* Sub arc machine
* Shear Punching
* Plasma Cutting
* Grinding Machine
* Ultrasonic flaw detector
* Drilling machine
* Saw cutting machine
* Gouging machine
* Pensile grinding machine
* The capacity / size of the above tools and equipment shall be judged in accordance with work conditions,
requirements, and availability at the time of execution
* Note: Safety officer will only check the availability and validity of registration, insurances and Quality fitness
certificates of plant, operator and equipment and its physical condition. Mechanical maintenance team should
inspect thoroughly the plant or equipment before its use on site that all are operational as per manufacturer’s
recommendations, specification and standards.

9.2 Manpower:

* Operations Manager
* Production Planning Engineer
* Production Engineer
* Welding Supervisor
* Welders
* Machine Operators
* Fabricators
* QC Inspector

10. PERMITS AND LICENSES REQUIRED:

All permits and licenses will be in place for required works

11. INSPECTION AND TEST REQUIREMENTS / QUALITY CONTROL

 All the inspections, testing (tests) and workmanship will be confirmed in full compliance with the
project specific specifications, through established inspection test plans and procedures. ITP
(JS19-010-ITP-FAB-Rev.00).

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12. HEALTH AND SAFETY AND ENVIONRNMENT

The Health and Safety of Negemco personnel is paramount our policy is to provide what is industry best practice.
All welfare facilities will be provided for the workers linked to toilets, rest shelters, drinking stations and first
aid these will be position at specified locations for use during the work scope.
All works will be covered by Health and safety personnel with monitoring taking place to ensure that all controls
are in place and working.

Induction Training and regular tool box talk will be given before commencement of any work

Personal Protective Equipment

As part of the work scope all parties involved in the work shall be provided with suitable PPE and it
is mandatory as the minimum standard to wear the following:

 Hard Hat
 Safety Footwear
 High Visibility Vest
 Nose Mask
 Safety Glasses
 Coverall
 Gloves
 Ear plugs/defenders

Note: Additional PPE will be supplied on request and due to any changes in the work scope that pose
additional risks to the workers.

13. EMERGENCY ARRANGEMENTS

The activities for emergency responses are to be in accordance approved emergency plan.

EMERGENCY CONTACT NUMBERS – NEGEMCO (STRUCTURAL STEEL MANUFACTURER)

Akram Dayab Project Manager 0797080003
M. Abdel Nasser QSHE Manager 0797071222
Iskander Salah Safety officer ( First aider) 0799270340
Murad Smadi Safety Engineer 0799270340
Musa Salameh Operations Manager 0798490017

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2.EMERGENCY SERVICES NUMBERS

Fire Brigade - 199

Mahaba Hospital - 053245541
Ambulance - 199

Police - 911
Musa Salameh Operations Manager 0798490017

14. REFERENCES DOCUMENTATION

 Fabrication drawings
 WPS
 PQR
 WPQ
 Personal Qualification
 packing list
 Material submittal
 MTC
 Approved Inspection & test Plan
 Inspection reports
 Qualified Welders List

15. Contract Documentation

 Contract Agreement
 Contract Drawings
 Bill of Quantities

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