MS--C-013 REV.

00

METHOD STATEMENT

FOR

STRUCTURAL STEEL FABRICATION & MODIFICATION

(Miscellaneous Structure & Embedded Items)

WASIT GAS PLANT SAUDI ARABIA

INDUSTRIAL SUPPORT FACILITIES (ISF)

KHURSANIYAH KINGDOM OF SAUDI ARABIA

Signature
00 July 18, 2011 Print Name A. Langcay E. Montejo R. Dimatatac G. Heo
Rev. DATE Prepared By Checked By Approved By Approved By
MMG MMG MMG SKEC

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I. SCOPE OF WORK

This Method Statement highlights the work sequence intended for the
fabrication of various structural steel elements/members and the modification
thereof. It defines the requirements for material selection, connections,
detailing, fabrication, galvanizing, painting and coating, marking for erection
(piece mark) and delivery of structural and miscellaneous steel structures.
Intended for structural steel fabrication for Pipe Rack, Pipe Support,
Equipment Structure & other embedded items such as insert plates, angular
frames and the like.
Execution of work shall be carried out in accordance with the relevant project
specifications and standard specified in the Saudi Aramco Engineering
Standard and other acceptable international standard.

II. PURPOSE

To ensure concrete pre-casting on various structural concrete foundations is

carried out safely and in good manner based on the safety rules and good
working practice set by Saudi Aramco/ SKEC to eliminate hazard and
minimize time consumed for casting the concrete structure foundations that
can be precasted off site. Precast concrete is done to eliminate the time
consumed in the preparation of materials and other pre-requisite prior to
casting it on site.

III. REFERENCES

Saudi Aramco Construction Safety Manual (General Instructions)

SAES-A-204 :Preparation of Structural Calculations
SAES-M-001:Structl.Design Criteria for Non-Building Structures
12-SAMSS-007 :Fabrication of Structural & Miscellaneous Steel
12-SAMSS-008 :Erection of Structural & Miscellaneous Steel
Saudi Aramco Inspection Requirements:
- Form 175-120100 :Steel Structures
- Form 175-120500 :Tower Communication
NMR-7927 :Non-Material Requirements for Fabricated Structl Steel
American Institute of Steel Construction (AISC)
American Society for Testing & Materials (ASTM)
American Welding Society (AWS)

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IV. EQUIPMENT & PERSONNEL

Fabrication Shop

MMG Fabrication Shop approved by Saudi Aramco to perform

the following scope of work:
- Fabrication of miscellaneous steel structure intended for
Pipe rack, Pipe support and Equipment structure.
- Fabrication of Embedded items such as insert plates,
angular frames, gratings and other related embedded
items.
- Fabricators responsibility to safeguard against
embrittlement and warpage per ASTM A143 & ASTM
A384. Fabrication details shall meet the requirements of
ASTM A385 to allow the creation of high quality zinc
coatings.
- Modification of any existing steel structure to suit the
requirement at site.
- Galvanizing and electro-plating works (if required).
- Protective Coating system for various structural steel.

Personnel

Fabrication Shop Structural Supervisor

Fabrication Shop Structural Foreman
Structural Steel Welders
Structural Steel Fitter
Structural Steel Worker
Structural Steel Detailer
Structural Steel Helpers

V. RESPONSIBILITIES / DISCIPLINE

Structural Supervisor

Prepare and arrange all necessary personnel, equipment, tools,

and materials and to provide schedule for the overall
implementation of the fabrication work.
Overall in charge to complete and assure an smooth flow of the
work and ensure compliance to the requirements of this
procedure, project quality control procedure/ test plan, relevant
drawings, safety procedure and the client specification.

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Directly responsible for assigning individual tradesman to

perform the given task.

Quality Control Inspector

A quality control program shall be instituted that will verify or ensure that
the work performed under the contract meets the requirements of this
standard and the design drawings as per Inspection document Sch. Q.
SAUDI ARAMCO shall have access to all facilities and records of the
Contractor & Sub-Contractor for the purpose of conducting performance
inspection/audits.
Conduct inspection in accordance with this procedure and approved
Quality Control Inspection Test Plan.
Monitor and visual inspection for every stage of the work during and after
the construction phase until the completion of the activity.
Independent testing agency or by the Contractors own laboratory
approved by Saudi Aramco Inspection Department can perform testing on
specific requirements of the work.
Test reference & Information of Third Party Inspection team submitted for
your review and final approval. We consider to employ the services of the
following third party:
Fugro Suhaimi, Ltd. (Independent Laboratory & Testing Agency), MMG
Transmittal No. MMG/SK-GS-T-S0029/2011.
Osaimi Engineering Ofiice (Independent Laboratory & Testing Agency),
MMG Transmittal No. MMG/SK-GS-T-S0030/2011.
QC staff Mobilization and function submitted separately, see MMG
Tranmittal Reference, MMG/SK-GS-T-S0002/2011 Quality Assurance
Plan & Resumes of Key Personnel.
All relevant material approval intended for this scope of work shall be
submitted separately.
Records and test results shall then be gathered and kept for future use and
reference.
Monitor daily structural fitting and welding works and ensure
compliance with Client specifications and Issued for Construction (IFC)
drawings.
Conduct activities in accordance with the Project QA Manual and
Quality Control Inspection Plan.
Prepare Q/C records and final acceptance documentation where
required.
Visual inspection on a daily basis during fabrication process.

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Engineering Department

Provide Technical support to site operation section; provide

AFC drawings and material specifications, standard and
technical specifications in controlled manner.
Responsible for review of Client drawings and data and the
resolution of technical work execution problems.
Provide Method Statement on the procedure of the work.

HSSE Requirement (by Safety Supervisor)

Ensure that job orders and necessary work perrmit are

available prior to commencement of any work.
Daily tool box meeting are to be conducted before start of the
work by the supervisor and the discussions will be
documented. Brief and educate personnel and their
compliance with safety requirements such as wearing
Personal Protection Equipment (PPE).
All workers shall wear minimum approved PPE such as hard
hat, safety glasses, gloves and safety shoes irrespective of
their location and the nature of the work. All personnel working
at heights shall wear full body harness with twin shock
absorbing lanyard.
All people involved shall undergo relevant HSSE Training as
per the project lost prevention plan.
Check work areas for any unsafe conditions. Liaise with Field
Supervisor and Foremen and make sure that work is carried
out in accordance with Project Safety Plan/ Procedure and the
feedback of Job Safety Analysis.
Persons working with power tools or pneumatic equipments
should wear hand gloves, ear plug and eye protection as a
minimum. Only trained and certified people are allowed to
work with such tools. Face protection will be worn while flying
particles potentially exist.
All operators, welders and steel workers involved shall be
Saudi Aramco certified and have undergone proper training
and well versed in the fabrication method.
All equipment, tools & accessories shall be certified and color
coded and of adequate capacity according to HSE
requirements.

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All equipments should be grounded prior to use. During the

fabrication, all electrical equipment shall be properly earthed.
During the activities, ie.. from loading of miscellaneous steel to
the fabrication to unloading of miscellaneous steel, relevant
preventive measures will be taken as per the HSSE
requirements.
Suitable safety barrier and sign boards will be used at the
work area to prevent the unauthorized entry of personnel and
vehicles.
Overhead crane in the fabrication shop shall be operated only
by a well trained personnel.

VI. WORK EXECUTION:

Structural Steel Fabrication

Prior to commence the fabrication of various structural elements
and its accessories, all relevant material, tools, equipment,
personnel and related documents are intact and made available
on site.
All fabrication shall be in accordance with the AISC Code of
Standard Practice for Buildings & Bridges and either the AISC
Specification for Structural Steel Buildings: Allowable Stress
Design and Plastic Design or the AISC LRFD Specification for
Structural Steel Buildings, as applicable, subject to modification
by the contract documents.
Reference to the approved drawing for structural fabrication, the
assigned steel worker (layout personnel) shall exhibit on the
physical steel structure the dimension to be cut, the degree and
the quantity of members that will constitute the whole structural
fabrication work.
Whenever practical, cutting, drilling and welding shall be
performed before galvanizing. The fabricator shall remove weld
slag before galvanizing.
The edges of tightly contracting surfaces shall be completely
seal weld.
The fabricator, before proceeding shall bring potential problems
that require modification in the design to the attention of the
designer.
Fabrication details shall be meticulously followed and extra care
shall be taken before and after cutting of the structural steel.

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The correct type of equipment shall be used in specific task.

Make sure that only inspected and acceptable tools and
equipment are made available on the working area.
The welding symbols used on plans and shop drawings shall be
per the American Welding Society (AWS). The field connection
symbols shall distinguished between assembly yard and
erection site connections.
All welding works shall be in accordance with ANSI/AWS
D1.1/D1.1.M. Structural Welding Code Steel or ANSI/AWS
D.1.3. Structural Welding Code, as appropriate.
Shop splices, substitution of member sizes or changes in details
and dimensions shall not be permitted without the approval &
permission of concerned departments.
In order to reduce field connections to a minimum, shop
assembly shall be as complete as possible, consistent with the
feasibility and economy. Long members shall be provided with
field joints of the same member strength.
All field connections shall be bolted and all shop connections
shall be welded or bolted, unless otherwise shown and specified
in the design drawings.
Lifting lugs for lifting of fully assembled structural units shall be
designed for attachment to primary structural members only.
All beams, except cantilevers, shall be fabricated with natural
mill camber in the up position. All re-entrant corners shall be
shaped, notched free, to a radius.
Base plate hole size for structural steel columns shall be as
follows:
- Anchor Bolts 3/41 (20-24mm) 5/16 (8mm) oversize
- Anchor bolts 1-2 (25-50mm) (12mm) oversize
- Anchor bolts 2 (50mm) -1 (25mm) oversize
All structural members shall be marked for identification and
shall be made acceptable by both party involved.
All similar members shall be kept together for easy identification
and shall be marked with piece mark.
Galvanizing of steel shapes, plates and hardware shall be in
accordance with the following ASTM specifications:
- Steel shapes & plates :ASTM A123
- ASTM A325 Type 1 or ASTM A325M Type 1 bolts and
corresponding nuts & washers- ASTM B695 or ASTM
A153/ASTM A153M.
- All bolts, nuts & washers shall meet required mechanical
properties after galvanizing.

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Embedded Items:
Embedded insert plates and Embedded Angular Frames on
concrete shall be as per ASTM A36/ASTM A307.
Fabrication of all insert plates shall be done based on the
dimension specified in the approved AFC drawings and shall
conform to Saudi Aramco specifications.
MS Plates shall be slitted to the specified dimension as
stipulated in the working drawing.
The corners of the insert plates shall be chamfered and smooth
grinded.
Lugs shall be provided to insert plates embedded on concrete
for good bonding purposes.
Spacing for lugs shall be specified on the working drawing and
measured on the physical structure on the fabrication shop.
The spacing shall be double check and confirm by QC
personnel.
The steel lugs shall be fully welded on the bottom of the insert
plate (fillet weld) and shall be smooth grinded prior to hot dipped
galvanizing.
All completed insert plates shall be checked and verified to its
dimension requirements.
Quality control inspector shall make a visual as well as test on
the said insert plates prior to fabrication.
Likewise, after the fabrication QC inspector shall also checked
and verify prior to hot dipped galvanizing.
All data shall be recorded and the DFT shall be measured to
conform to the Saudi Aramco requirements for coating system.

Modification Works:
Any modification to be carried out in the fabrication work which
involves welding activity, a qualified welder shall be utilized based
on Aramco approved welding procedure AWS D1.1.
Work shall be as per the detailed AFC drawing and duly approved
by the concerned department regarding the portion to be modified
or rectified.
Approved working drawing with specific directives shall be issued to
fabrication to modify the structure found not conforming to the
project requirements.
All dimensions and notations shall be meticulously observed and
care should be taken to complete the modification procedure.

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When total work is nearing completion, a punch list on all steel

structures shall be prepared and any work omitted for any reason of
construction damage will be noted and corrected as per the
specification.
Touch-up all rectified structures with organic zinc paint material
recommended by steel fabricator or as per material approved by
Saudi Aramco.
Maintain a good housekeeping at all times.
Carry out QC inspection of the marks and obtain approval.

VII. QUALITY CONTROL AND ASSURANCE

All stages of work shall be inspected in accordance with the Approved

Project Quality Control Inspection Test Plan.
Visual inspection on a daily basis by QA/QC Structural Works.

VIII. SITE HEALTH AND SAFETY

The work shall be executed in accordance with the approved job safety
analysis. Work permit shall be obtained prior to any commencement of
the work when required.

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