Method Statement With Job Safety Analysis For Process Units Foundation Works (Rev 1) (13-08-2019)

Conex Petroleum Refining Company
Project Name 10,000 BPD PETROLEUM REFINERY AT FREE PORT MONROVIA
Site Contractor LUTECH ENGINEERING FZ LLC Issued For Review and

Approval
Document No. Rev. 1 Date 23/08/19
METHOD STATEMENT WITH JOB SAFETY ANALYSIS

FOR PROCESS UNITS FOUNDATION WORKS
PROJECT
10,000 BPD Petroleum Refinery at Free Port

Monrovia
August, 2019
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Lutech Engineering FZ LLC
Title Method Statement with Job Safety Analysis for Process Units Foundation Works
Document No.
Project 10,000 BPD Petroleum Refinery at Free Port Monrovia
Contract No.
Client Conex Petroleum Refining Company
Contractor Lutech Engineering FZ LLC
Total No. of Sheets:
Rev Remarks Prepared By Prepared Checked By Checked Approved By Approved

No. Date Date Date
Draft 13/08/19
REV 1 23/08/19
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TABLE OF CONTENTS
Sr. No. Description

1.0 PURPOSE
2.0 SCOPE
3.0 REFERENCE DOCUMENT
4.0 GENERAL
5.0 METHODOLOGY
6.0 JOB SAFETY ANALYSIS & MITIGATION MEASURES
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1.0 PURPOSE
Lutech Engineering is going ahead with construction of 10,000 bpd petroleum refining
for their Client M/s. CONEX Petroleum Refining Company at Monrovia Free port,
Liberia consisting of OSBL tankages, ISBL tankages, Piping, Pump house, Dyke wall,
Refinery Civil construction, Erection of Refinery Columns, Heat exchangers, Heaters,
Boilers along with necessary Control Room / Office Building, Road, Drains, Culverts,
Cross overs etc. All related necessary job of integration with existing CONEX terminal
facility to that of proposed Refinery facilities including Tankages, pumping to be
carried out to facilitate Export of product through existing Shipping line and local
delivery by BRVs.
Various Process Units such as Crude Distillation Unit, Strippers, Heat Exchangers,
Vessels, Coolers, Pumps near to CDU, Stripper unit will necessitates Civil foundation
on which these equipments can be erected. Similarly, there will be a pump house,
Utility with steel structure canopy which will necessitate appropriate Civil foundation.
Various building / structure will be required for the Refinery Operation including an
Administrative building cum Control Room, a Warehouse / Shop building and a PMCC.
The Method statement describes the sequences and methods to adopt for the
Construction of Process Unit Foundation work procedures and sequence of activities
carried out to complete the foundation work. The procedure explains systematic
methodology for various Activities and sub activities to work along with the required
Quality measures and Safety precautions / mitigation measures needed through Job
Safety Analysis, to be carried out during Work Execution.
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2.0 SCOPE
This document explains the required activities to carryout Civil foundation work
pertaining to Refinery Process Units like CDU, Heater, Strippers / Columns, Heat
Exchanger etc. and all other Utilities Building or Steel Structure / shed like Pump
shed, PMCC, Ware house / Workshop / Laboratory, Control Room, shed for Air
Compressor, Nitrogen generator, Boiler etc. as per approved Lay out.
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3.0 REFERENCE DOCUMENT
1. Contract Document
2. Lay Out covering ISBL area including CDU, Heater, Control Room, PMCC, Utilities
etc.
3. Civil Drawings for Structure and or Foundation for Building, Steel Structure with
shed of various Utilities, Pump shed, Control Room, Ware-House / Shop /
Laboratory
4. Drawing for RCC Mat foundation for all Process Units covering the area indicated in
Lay out.
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4.0 GENERAL
It has been proposed to carryout Civil foundation work pertaining to Refinery Process
Units like CDU, Heater, Strippers / Columns, Heat Exchanger etc. and all other
Utilities Building or Steel Structure / shed like Pump shed, PMCC, Ware house /
Workshop / Laboratory, Admin Building / Control Room, shed for Air Compressor,
Nitrogen generator, Boiler etc. as per approved Lay out.
Equipment’s & Accessories:
1. Earth Moving Equipment’s: Excavators, Front Loaders, wheeled Loading shovels

2. Construction Vehicles: Tippers, Dumpers, Tankers (Water)
3. Material Handling Equipment: Crane, Hoist, Forklifts (as needed)
4. Construction Equipment: Concrete Mixer, Compactor, Road Roller, Concrete Pump Truck,
Vibrator
5. Other Equipment: Total Station, Measuring Tape, Explosimeter, etc.
4.1 MATERIAL & QUALITY CHECK REQUIREMENTS
Material which shall be used for RCC work will be as under:
Cement: As per Mix design requirements. Portland cement shall be used. The criteria
for selections are as follows as per IS 456 / IS 269 / IS 1489 / IS 12269
1. Fineness
2. Compressive Strength
3. Initial & Final setting time- Initial setting time not less than 30 minutes and final
setting time not to exceed 10 hours
Coarse Aggregates: As per mix design requirements and as per IS 383 / IS 456
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The criteria for selections are as under:
1. Determination of Particle size (Sieve Analysis)

2. Flakiness Index
3. Crushing Value
4. Specific Gravity
5. Bulk Density
6. Absorption Value
7. Moisture Content
8. Soundness of Aggregate
9. Presence of deleterious materials.
Fine Aggregates: As per mix design requirements and as per IS 383/ IS 456
1. Gradation / Determination of Particle size

2. Specific Gravity and density.
3. Moisture Content
4. Absorption Value
5. Bulking
6. Silt content test
7. Presence of deleterious materials
Water: The Water used for mixing concrete shall be fresh, clean and free from oil,
acids and alkalis, organic materials, or other deleterious materials. As per IS 456 / IS
3025 and Lutech Specification
1. Cleanliness (Visual Check)
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2. Chemical and physical properties of water for checking its suitability for
construction proposes.
Reinforcement Steel: Generally, Fe 415 with Yield Strength of 415 MPa shall be used
for reinforcement.
The criteria and test methodologies are as under:
1. Identification & size: Random

2. Chemical Analysis Test: One sample per lot
3. Tensile strength: One sample per each size
4. Yield Strength: one sample per each size
5. Percentage Elongation: one sample per each size
6. Bend / Rebend Test: one sample per each size
7. Reverse Bend Test for HYSD wire: one sample per each size
Quality Checks Requirement:
Before Excavation:
Checks shall to be carried out 100%.
• Checking of pegs location as Per line and alignment

• Checking of pit making as per Drawing & RL
Excavation:
Checks shall be carried out at each Location.
• Dimensional conformity
• Verticality / slopes & Shape - Square or Circular of each pit
• Verification of classification of foundation wherever applicable.
PCC Padding:
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PCC padding shall be done as per design, drawing and specification.
Checks shall be carried out for all Locations
Steel Bar Reinforcement Work:
• Check visually the steel bars for rust, cracks, surface flaws, laminate etc.
• Check as per the Bar bending schedule before placement of concrete.
• Check the Test Certificates from OEM for each lot and each size.
• Check cutting tolerance for bars as per check List / drawings. Check whether all
bent bars and lap lengths are as per approved bar bending schedule.
• Check whether all joints & crossing of bars are tied properly with right gauge &
annealed wire as per specification.
• Check for proper cover distance spacing of bars, spacers, & chairs after the
reinforcement cage has been put inside the formwork.
• Check whether lapping of bars are tied properly with right gauge and annealed
wire as per specification
Form Work:
• Check for materials, breakage or damage

• Check for plumb, alignment, parallelism, Shape- Square or Circular and
equidistance from stub
• Dimensional check for level and height
• Check for rigidity of frame / tightness
• Cleaning and oiling
• Diagonal / intermediate bracing with steel clamp if required as per site conditions
• Checking of joints to avoid undue loss of cement slurry
Concreting:
Concreting work will follow C 30 (generally) Mix. Each Mix to be checked 100%.
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• Batching, mixing & placing of concrete and compacting

• Placing concrete, and compacting
Concrete Testing:
• One Slump Test for per foundation work

• Check for quantities for cement, fine aggregate, coarse aggregate and water while
batching - 100% on all location
Concrete Cube Testing:
As per BS-EN-12350
• Compressive Strength - Sample (Consisting of minimum 3 cubes) to be collected for

7 days & 28 days’ strength test. Minimum Compressive strength should not less
than 25.5 MPa after 7-day test and 38.25 MPa after 28 days.
Back Filling:
Checks to be carried out 100%
• Check for thickness of layer and watering,

• Visual check for correction, ramming
• Compaction test (percentage of Max dry density)
Brick / CC Block Work:
Random checks to be carried out for all Brick / CC block work.
• Mortar mix / proportion as per IS 2250

• Plumb & Alignment Joints
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Plastering:
Plastering shall be done as per approved design and specification document. The
Plastering shall be checked at Random.
• Plastering thickness and evenness

• Mortar Mix proportion
Curing for Concrete, Masonry and Plastering etc.:
Checks shall be carried out 100%
4.2 FOUNDATION WORK: BUILDINGS & STEEL STRUCTURE
Various buildings will be required for the refinery operation including an

administration building, a warehouse / shop building, and an MCC room and a control
room. Based on the number of personnel required to operate the refinery, we
recommend the following building sizes:
1. Administration building – utilize the existing PST office building.

2. A modular MCC building 12 feet wide by 36 feet long with space for the electrical
panels (Motor Control Center or MCC) and an operator station.
3. A modular Control building 12 feet wide by 36 feet long with space for the control
PLC panels and two (2) operator stations for the CDU and OSBL / tanks.
4. A warehouse / shop / laboratory building. Likely building size is 1,500 square feet
(30 feet wide by 50-feet long by 16-foot eave height). Building shall include with
three (3) mandoors, two (2) 10’ X 12’ overhead doors, one (1) 5-ton crane,
insulation, interior overhead lighting, etc. This building shall include a 12-foot by
15-foot laboratory room and a 12-foot by 13-foot maintenance office.
5. A canopy over the pumping station and HFO skid, sized at 15 feet wide by 60 feet
long.
6. A canopy over the utility area (boiler, air compressor, power generators) sized at
20 feet wide by 55 feet long.
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The Process involves the following steps for individual foundation for each of the
above:
1. Identification of Location / coordinates

2. Bar Bending Schedule & RCC Mix Design
3. Excavation of earth based on foundation design
4. Removal of earth from site
5. Shoring as necessary
6. Dewatering, as needed
7. Hard soling (Crush rock) & compaction
8. PCC Padding
9. Form Work & Installing Steel Reinforcement
10. Casting of Footing
11. Form Work &Casting of RCC Pedestal / Column Foundation (including Anchor Bolt
Installation for Steel Structure)
12. Quality Control Checks
13. Curing
14. Removal of Form work
15. Sand / Earth Back Filling & Finishing
16. Superstructure Work (CC Block Installation)
17. Plastering of Superstructure
4.3 FOUNDATION WORK: PROCESS UNITS
The area covering CDU, Heater, Strippers, Columns, Heat Exchangers etc. is about
1250 Sq. M (CDU Area- 50 M X 25 M) which shall have RCC Mat foundation.
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The Process for foundation will be as under:
1. Identification of Location / coordinates

2. Bar Bending Schedule & RCC Mix Design
3. Excavation of earth based on foundation design
4. Removal of earth from site
5. Dewatering, as needed
6. Shoring as necessary
7. Hard soling (Crush rock) & compaction
8. Form Work
9. PCC Padding
10. Form Work & Installing Steel Reinforcement
11. Quality Control Checks
12. Casting of Footing
13. Form Work & Casting of RCC Mat Foundation (including Installation of Anchor Bolt)
14. Curing
15. Removal of Form work
16. Sand / Earth Back Filling & Finishing
• All excavation works are equivalent to Hot Work. Excavation Permit needs to
obtained from Terminal Manager for Excavation and all other Cold Work. Electrical
Clearance is also necessary for any possible Electrical Cable or possible Earthling
Network, on a one-time basis. Similarly, Custodian will issue Clearance for any
possible Sewerage line in proposed New Tank Farm site.
• Fire screen of 3 M high has been provided after the existing Tank Farm to isolate
the Proposed New Tank Farm. All ignition sources shall be kept off as far as
possible. Tool Box Talk is a must before start of the job on a daily basis, as the
situation, working / operating condition may change overnight or changes in shift.
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The Other supporting activities are as under:
• Traffic Management Plan: It is proposed to use the Emergency exit of the Terminal
for Incoming / outgoing traffic related project related material movement and
other mobile equipment like Excavator, Hydra, Mobile Crane, Concrete Mixer
Truck, Other material trucks, Staff / Contractor men vehicle etc. However, as the
proposed route is not in good motor able condition, it is suggested to use the
existing main Entry route to Terminal for these Project related Vehicle / Mobile
equipment’s, which is passing by the side of existing Tank Farm to the Project site
with a another separate Entry and Exit at the area contiguous to Tank Farm end
leading to Terminal Exit gate.
• Security: All vehicles / Mobile equipment’s will pass through Terminal Security
with appropriate Gate Pass (Entry / Exit).
• Materials: All materials pertaining to Project will be stored in designated area as
earmarked by the Site Engineer. Site Engineer need to consult Terminal Manager in
this respect, as needed.
• Any surplus earth out of excavation, will be disposed-off, by Site I/C to create
enough space to accommodate Project Materials and to provide adequate space for
carrying out jobs, movement of Mobile equipment’s etc.
• In view of ongoing monsoon all approaches to Project site and within Site shall be
made motor able or at least WBM / WMM type.
• All safety and security arrangement shall be in place and Terminal Operations shall
not be hampered.
• At least 2 X 9 Kg DCP Fire Extinguishers, Sand buckets (dry sand) and one running
water hose near work area shall be in readiness to meet Emergency.
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5.0 METHODOLOGY
5.1 The Methodology for Civil job for Process Equipment Foundation and Other Structural
/ Building Foundation work will be as under.
Identification of Location / Coordinates:
• Check the approved Layout and drawing for the facility for which foundation is
required.
• Use Total Station and mark the Northing, Easting and Reduced Level (Elevation
above Datum Level) at the site
Excavation:
• Obtain excavation Permit, check whether any Utilities exists such as electrical
cable, Earth grid, Air / water line, Gas line, Sewerage line in the area identified
for Excavation. Electrical isolation may be required for any Live line, as needed.
Services, wherever found shall be rerouted and protected to place will not affect
site activities.
• Engineer / Surveyor would conduct the site survey to mark /stake-out the lines and
levels of the objective excavation for foundations as per indicated in the approved
drawing.
• The area to be excavated shall be properly marked and clear before starting the
works.
• The depth of excavation shall be periodically checked by a surveyor to avoid over
excavation. the bank of excavated area shall be sloped 30 degrees and shall be
maintained to avoid a collapse of the bank into the excavated area.
• All excavated material shall be kept a minimum of 1.0 meter from the edge of
excavation or shall be stockpiled to the area designated by the Engineer.
• For all excavation activities, adequate safety barriers, sign boards, advance
warning signs would be used.
• For foundation, as soon as the excavation reaches the required depth / elevation
the surface shall be leveled and shall be compacted to 95 % of maximum dry
density or MDD.
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• Before the compaction starts, it shall make sure that the excavated level is free
from standing water or excessive moisture content.
• Inspection would be conducted during compaction for checking and approval of the
Engineer.
• The compaction test report shall be submitted to the Engineer for approval prior to
precede succeeding work.
• Anti-termite treatment would be conducted prior to start blinding works but make
sure the anti-termite material is approved by the Engineer, as needed.
Dewatering:
As the site has an elevation of only 5 Meter and the water table is very high especially
during monsoon, it requires dewatering even after an excavation depth of 1 - 2 Meter.
Thus any foundation work involves dewatering.
• Protect structure, prepare and adjust to the site from damage caused by
settlement and hazards created by dewatering.
• Any closing of roads, streets, or facilities shall be with permission from authority
has jurisdiction and then provide alternative access.
• The header pipe shall be connected to well points placed at 1 meter centers with
sufficient depth to ensure that lowering of the water table shall be carried out
from a level not less than 1 meter below the excavation bottom.
• Pre-drilling will be carried out prior to installation of the well point, followed by
high-pressure water jetting, to flush out sand and create mini well.
• A filter media of 3/16 inches (3 – 5 mm) screened black sand shall be inserted
around the 3/4 depth of the wells to act as barrier against fines and prevent
choking of well points.
• Operate the dewatering system continuously 24 hours a day or as needed, to drain
and to fill construction material and until written by authorization to cease
dewatering.
• All the header pipes will be connected to discharge area to a suitable drainage
system which is approved by authorities jurisdiction. If water contained any oil or
grease, allow the water to pass through OWS.
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• Dispose the water removed in a manner to avoid endangering public health,

environment, and neighboring property
• For safety purpose, provide safety barrier along the perimeter of the excavated
area to prevent fall hazards.
Compaction:
• Uses generally 150 mm- 200 mm crush rock for compaction and or as per design
and specification document and spread them uniformly on area demarcated for
foundation
• Appropriate approach to excavated site shall be made for Compactor movement.
• Only authorized and Certified Compactor and Operator shall be engaged.
• Use Roller / Compactor not less than 10 Ton on every layer
• Void shall be filled up with 50 mm - 100 mm crush rock and or as per design and
specification document.
• Measure the depth periodically till get crush rock thickness obtained as shown in
drawing.
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PCC Padding:
• PCC padding shall be provided as per approved drawing, design and specification
• Concrete mix shall be frozen as per specification provided. Generally, 40 mm
Aggregate suggested or as per approved specification.
• C 30 concrete shall be used generally and or the Concrete specification will be as
per approved design, drawing and specification document.
• Batch Plant Mix test report shall be verified
• Form work shall be carried out as appropriate for the site condition and in line
with design and drawing of foundation work.
• RCC mix used shall not exceed temperature of 30 Deg C
• Compaction by Vibrator shall be carried out
• Void shall be filled up with cement slurry.
• Carry out Cube test as per norms after 7 days and 28 days
• Curing shall be done in moist environment as per standing practice.
Form Work:
Generally, the timber formwork is to be used when limited reuse of formwork is

required. As for requirement of maximum reuse of formwork, the steel formwork is to
be used.
Formwork Design - Both types of formwork shall be designed to meet the following
requirements:
• The structure dimensions indicated in the construction drawings.

• Stability of the formwork (both vertically and laterally) in the initial position
during or after concreting.
• The surface finish shall be as per the required type.
• The formwork shall allow proper concrete placement and vibration.
• The formwork shall be well tight to prevent mortar loss.
• The formwork shall withstand the pressure of the fresh concrete and, dead and
live loads as well as re-shoring loads in structures.
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• The form shall support solidly and in accurate positions, all the embedded items
placed as per construction drawings.
• Ties will be placed at such intervals that will not allow any movement or
deformation of the formwork beyond the specified tolerance limits. Forms for
small section elements, i.e., columns, shall be tied externally. Through-ties shall
be used for big area forms. Ties shall be locked through steel clamps outside
through reinforcement steel passing across Form work at top and bottom.
• Prior to concreting, the form shall be cleaned and any foreign material shall be
removed. If necessary, openings shall be provided in the formwork for the removal
of the foreign materials. Before placing the formwork, it will be coated with the
approved release agent. The properties and coating procedure shall conform to
project specifications.
• Formwork for columns, sides of beams, walls (except for tank foundations) and
other formworks not supporting the concrete weight shall be removed.
• All shoring and propping requirements shall be submitted to client for approval.
• All exterior exposed corners shall be chamfered as indicated in the construction
drawings.
Reinforcement:
The reinforcing steel shall be conforming to project specification and as per drawings.
• Each bundle of bars will be tagged to be identified by the design drawing number,
the structure, mark number, bar quantity and size.
• The reinforcement will be cut and bent in accordance with the approved bar
bending schedules.
• The bending of reinforcements will be done on the bending machine, producing a
gradual and even motion. Bars will be bent cold and at specified radii.
• The rebar received from the supplier will be inspected. All defective materials will
be repaired or replaced by the supplier.
• The storage of rebar will be arranged above ground on padded supports, using
timber pieces or sand bags.
• Minimum concrete cover for reinforcement shall be as per the approved Reinforced
Concrete Works General Notes or Design document.
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• All reinforcement shall be supported and fastened before concrete is placed and
shall be secured against displacement within permitted tolerances.
• Reinforcement supported by formwork shall rest on bar supports made of plastic or
other acceptable materials.
• All splices will be provided as indicated in the approved for construction drawings.
• Bending or straightening of bars partially embedded in concrete will not be
permitted without prior approval of the Site Engineer.
• The reinforcement at obstructions or where it clashes with another reinforcement
will not be cut, bent, omitted or modified without prior approval from the Site
Engineer.
• The welding of reinforcement will not be permitted.
• Fixing of Reinforcement-
• The reinforcement will be accurately fixed in the required position. The bars
intended to be on contact at passing points will be securely tied together at all
such points with PVC coated tying wire.
• After fixing, the reinforcement will be inspected for type, size, and accuracy of
placing. The areas where the coating will be found to be damaged it will be
repaired as per approved method statement.
• The reinforcement projecting out from work being concreted or already concreted
will not be bent out of its correct position. It will be protected from deformations
or other damages.
• The cover to reinforcement will be maintained by using concrete blocks.
• Cantilever and top bars over supports will be held in correct position during
concreting with the help of rebar chairs placed between top and bottom bars and
approved spacers below the bottom bars.
Quality Control-
The reinforcement will be inspected before concreting. It will be ensured that the
surface of reinforcement will be free from mud, oil, retarders, grease or any other
substance which would affect adversely the steel or concrete chemically or reduce
the bond. Also it will be ensured that it is placed in full accordance to the issued for
construction drawings.
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Embedded Items-
• All the embedded items will be fabricated or procured prior to concreting and
fixed in place using suitable templates.
• Suitable templates will be designed for the positioning and fixing of the embedded
items including foundations for large Skirt Mounted Vessels.
• The adequacy and positioning will be checked by the Site Engineer before
submitting a Request for Inspection to the QC Manager. The QC will check them in
turn before forwarding this request to the QC of the Contractor. This procedure
ensures the right kind of embedded items are in right place and in right quantities.
• Anchor bolts will be placed plumb well within the tolerances mentioned in project
specifications.
Concreting:
Delivery of Concrete-
• Before discharging the concrete at the point of delivery, the driver will provide the
Engineer or Quality Control Engineer the delivery ticket identifying the material
for each batch of concrete.
• Out of the available transit mixer trucks, at least one will be kept as stand by.
Before the departure of the loaded transit mixer, the delivery ticket will be
handed over to the driver.
• The concrete will be conveyed to the place of placing in the following manner:
o Metallic or Metal-lined chutes

o Concrete Pump: The concrete pump will be of adequate pumping capacity.
Wherever required, the concrete will be pumped through steel pipes.
• The concrete will be deposited continuously or in layers of such thickness so that

cold joints are not formed. The concrete, which has partially hardened, will not be
deposited. Suitable construction joints will be provided to avoid formation of cold
joints.
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• After placing, the concrete will be consolidated by using mechanical or electrical

vibrators, which will be operated by competent workmen. Use of vibrators to
transport concrete within the formwork will not be allowed.
• Unless adequate protection is provided, concrete will not be placed during rain.
Curing of Concrete-
Immediately after placement, concrete will be protected from premature drying and
excessively hot temperatures and will be maintained with minimum moisture loss at
relatively constant temperature for a period necessary for the hydration of the
cement and hardening of the concrete.
The curing of concrete will be carried out by one of the following procedures:
1. Pouring or continuous sprinkling of water.

2. Application of hessian kept continuously wet and covered with white polyethylene
sheet.
3. Application of sand kept continuously wet.
4. Application of waterproof sheet material subject to approval by Client.
5. Application of curing compound subject to approval by Client.
The system to be used will depend on the nature of the structure. The above methods
(2) and (5) will be the mostly used.
Moisture loss from surfaces placed against wooden forms or steel forms, exposed to
heating by sun, will be minimised by draping forms with wet hessian covered with
white polyethylene until they can be safely removed. After forms are removed, the
concrete will be cured up to the end of prescribed period.
Quality Control:
• The workability of the concrete will be continuously monitored at delivery place

before casting.
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• Samples for conducting tests for determining the compressive strength on concrete
will be taken according to the specifications.
• Concreting will be carried out using the approved design mixes and that specified
for the structure. The concrete from approved sources only will be used for all
concreting works.
• All rebar and forms will be cleaned of debris and foreign materials before pouring.
• It will be ensured that the temperature of concrete at the time of placing does not
exceed more than 30° C.
• The concrete pouring will be done within the initial setting time of the cement.
For the purpose of this, the time of batching as marked on the delivery sheet will
be considered.
• During hot weather, reinforcement temperature will be reduced by shading, water
spray before pouring as well as additional crew will be engaged to expedite the
finishing etc. However, preference for night pouring of concrete will be given.
• The concrete will then be poured into the mould I form after ensuring that it is
free of all foreign materials or debris, the inserts are in place, the re-bars are as
per the drawings and all other QC requirements are complied with.
• The concrete surfaces will be rendered appropriate finish to eliminate all voids and
pits unless specified otherwise in the drawings.
• The concrete will be laid in layers not exceeding 300mm in thickness; each layer
compacted separately before the next is laid.
• At least two vibrators of needle type will be made available at the site, where one
of them acts as a stand-by.
• In case of mass pouring, the concreting will be done uninterrupted so that cold
joints can be avoided. However, in case of slabs/ paving appropriate pre-approved
construction joints will be provided.
• Concrete surface will be finished as per specifications within the initial setting
time of concrete. Immediately after finishing surface shall be covered with white
polyethylene sheeting which shall be in contact with concrete surfaces to avoid
evaporation of moisture content from fresh concrete.
• Control joints, if any, will be cut within 12 hours after placing of concrete.
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Testing of Concrete-
• A third party laboratory (preferably Government or Institute) as approved by the

Client will be appointed to carry out tests on concrete as may be applicable as per
project specification.
• Temperature, slump, unit weight and air content of fresh concrete shall be
measured at the point of pour, prior to placement in forms. Concrete not
conforming to the requirements of the specification shall be rejected. Test sample
cylinders will be collected in accordance with project specifications.
• Temperature of fresh concrete will be recorded in accordance with specification
requirement. Test Cylinders will be dated and numbered consecutively. Each
cylinder of each set will also be given an identifying tag (A, B, C, D).
HSE Plan:
All safety measures will be observed during the entire works. Detailed safety
measures for every works will be elaborated by drawing JSA. The basic HSE plan is as
under-
• All the activities will be envisaged a week in advance and job safety requirements
shall be worked out by analyzing the likely hazards and resorting to mitigation
measures.
• Proper house-keeping at the end of the day is a part of the mandatory tasks
assigned to workers to avoid accidents due to littered tools and materials.
• Flagmen will be engaged to control the movement of trailers, cranes, pumps and
other mobile equipments.
• Daily tool box talk shall be conducted and brief safety measures required for the
ensuing days shall be discussed.
• First aid facility shall be available through the entire period in the work site.
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Installation of Anchor Bolt:
One of the most challenging jobs in the construction of steel structure is the
installation of anchor bolts where it is considered to be an ankle joint of a steel
column. It is to be ensured that the process is true against the approved drawing and
the most important; it should be within the safe working condition.
The concerned Engineer shall check the approved Anchor Bolt shop drawing, Material
submittal for Anchor Bolt, Place specification (size- Anchor Bolt, Nut, Washer).
• Use approved drawings for work preparation.

• Use approved materials as per approved drawings such as anchor bolts length,
diameter, number, and location.
• Use Total Station for exact Location, Level, and Position for Anchor bolt
installation.
• To fix the anchor bolts prepare a temporary wooden plate contains holes relevant
to the diameter, location and number of anchor bolts as per approved drawings.
• Fix the bolts in the temporary wooden plate accurately.
• Prepare the axis in the top of the neck columns in order to fix the anchor bolts.
• After survey works, start fixing the temporary wooden plate with the anchor bolts
in the top of the neck columns.
• Insert the bottom part of the anchor bolts inside the neck columns as per approved
drawings.
• After fixing the temporary wooden plates align, level and fix properly the anchor
bolts as per approved drawings.
• The surveyor has to check the alignment and the level of the anchor bolts after
fixing.
• The Engineer shall check the anchor bolts after fixing.
• After Engineer’s approval cover the anchor bolts with masking tape protection
before concreting.
• Approve for concreting after ensuring Level, Location and alignment check by QC
Engineer.
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Figure: TYPICAL SHOP DRAWING FOR INSTALLING ANCHOR BOLT
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Figure: RCC PEDESTAL FOUNDATION FOR PUMP HOUSE
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Figure: FOUNDATION OF RCC PEDESTAL FOR UTILITY AREA STEEL CANOPY

STRUCTURE
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FIG: SUGGESTED PLAN of RCC MAT FOUNDATION FOR CDU AREA (50 M x 25 M)
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FIG: SUGGESTED RCC MAT FOUNDATION FOR CDU AREA (50 M x 25 M)
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6.0 JOB SAFETY ANALYSIS TEMPLATE
Job Title: Process Unit RCC Foundation Page _____ of _____ JSA No.: Date: _____ New _____ Revised
work
Equipment: Supervisor: Analysis by:
Department: Approved by:
Required Personal Protective Equipment (PPE):
Job Steps Potential Hazards Recommended Safe Job Procedures & Mitigation Measure
Identification of Location / coordinates Injury As per Methodology statement. Obtain Cold Work Permit. Use
PPE (Helmet, Safety Shoe). Fence the area. Put up Caution
Board.
Bar Bending Schedule Injury As per Methodology statement. Obtain Cold Work Permit. Use
PPE (Helmet, Safety Shoe, Hand gloves). Check for the
stability of the equipment. Only trained and competent
Contractor staff.
RCC Mix Design
Route Fixation for Movement of Material & Mobile Incident involving Truck / Route must be fixed / ear marked and Motor able or hard top
equipment’s mobile equipment, Injury, type. Truck / Mobile equipment speed limit - 10 KMPH within
Death, Loss of property / Project site / Terminal. Detachable Spark Arrester to be fixed
material on Mobile Plant. Competent and or having valid license to
drive / operate. Terminal Staff to follow earmarked for
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pathways for pedestrians.
Excavation of earth based on foundation design and drawing Injury or Illness Obtain Excavation Permit. Fence the area. Put up Caution
Board. Appropriate Entry / Exit for excavated pit.
As per Methodology statement.
Site Engineer and other working staff to be aware of

Electrical Cables, Sewerage line, defunct Petroleum line
passing through site. Consider enough space for movement of
Excavator in Horizontal and vertical direction. Almost 2 M
depth earth excavation needed. Area fenced- only authorized
and competent people to work. Excavated earthed to be
positioned at least 1 M away. Site Engineer to consider
condition of earth due to prevailing monsoon, static load and
dynamic load in surroundings, Stability of Excavation. Assess
any live service, proximate water course or isolation failure
could cause flooding of excavation. Means of entry and exit
from the excavation. Dewatering pump. Any Mobile Plant
must not be allowed within 2 M from Electrical Cable and Pole
within 5 M.
Removal of earth from site Injury Working / proper earth mover / dumper/ Front loader.
Competent operator / driver. Site Engineer to direct the area
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Approval
of safe operation considering Static and dynamic load on
excavation. Flagman to direct traffic for safe movement
Shoring as necessary Injury Shored, benched and or battered, as needed. Sloping of the
face prevent ground collapse. Benching and battering may
also be considered in absence of shoring.
Dewatering Injury / Environment As per Methodology statement. Dewatering Engine to be
Pollution fitted with spark arrester. Ensure that mud; slurries are not
drained on discharge side. In case of Oil and grease presence
in water, report to Client. Oily water shall be drained through
OWS. Nearby facilities need to be protected whose structural
stability might get disturbed because of dewatering. Protect
them with appropriate Timber or Steel plate supported with
Steel pipe to avoid possible earth collapse causing damages to
foundation of nearby facilities. Use PPEs
Hard (Crush rock) soling / Compaction / PCC Padding Injury As per Methodology statement. Protection from earth
collapse. Providing shield. Sloping of the face prevent ground
collapse. Use PPEs
Form Work / Shuttering Injury As per Methodology statement. Protection from earth
collapse. PPEs (Gloves, Helmet, Safety Shoe).
Installing steel Reinforcement Injury As per Methodology statement. Protection from earth
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collapse. PPEs (Gloves, Helmet, Safety Shoe).
Positioning of aggregate, Concrete Mix Injury Demarcated area. PPEs.
Positioning of necessary equipment’s for concreting work Injury Demarcated area. PPEs.
RCC Work of Footing Injury As per Methodology statement. Protection from earth
collapse. PPEs (Gloves, Helmet, Safety Shoe, Dust mask).
Safety shower be provided.
Casting of RCC Mat Foundation / Column / Pedestal (with Injury As per Methodology statement. PPEs (Gloves, Helmet, Safety
anchor Bolt) Shoe, Dust mask). All mobile Plants to be fitted with Spark
arrester (detachable). Safety shower be provided. Flagman to
control movement of traffic.
Curing of Concrete Injury As per Methodology statement. PPEs (Gloves, Helmet, Safety
Shoe)
Removal of shuttering and disposal of shuttering materials Injury PPEs (Gloves, Helmet, Safety Shoe)
Sand / Earth back filling& compaction Injury As per Method Statement. PPEs
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General Personal Protective Equipment’s
Type of Protection PPEs Remarks

Head Hard hat / Helmet - meets ANSI Z89.1 Name should be displayed for
requirements identification
Eye & face Safety Glass – meets ANSI Z87 requirements Person wearing prescription glass to
wear over the glass
Foot Steel toed shoe / boot Tennis shoe, sandals not allowed
High Visibility Attire Vest with high visibility - meets ANSI Welders excluded
reflectivity requirements
Hand / Finger Appropriate Gloves People using tools / materials to use
always
Hearing Ear plug - used for noise more than 85 dBA Exposure not to exceed 140 dBA
Activity based Eye / Face Protective Equipment’s:
Activity Safety Equipment

Welding Welding Hood and safety glasses with side shields
Burning Burning Goggles with Shield
Abrasive grinding or cutting Face Shield and safety glasses with side shields
Drilling Goggles or Face Shield and safety glasses with side shields
Reaming Face Shield and safety glasses with side shields
Chemical Handling Goggles and Face Shield
Molten Materials Goggles and Face Shield
Corrosive Liquids Goggles and Face Shield
Concrete Pouring Safety glasses with side shields
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Approval
Activity based Protection Equipment’s:
Activity Safety Equipment Remarks / Protection System

Vessel / Confined Space Entry Self-Contained Breathing Apparatus Gas / Oxygen / H2S test to be
checked, Adequate Ventilation &
Illumination
Working at height / Operating Safety harness / Safety belt Protection fall arrest system / Proper
Mobile plant guard rail / scaffolding / safety
netting / certified mobile Boom Lift /
Crane / Excavator / Front Loader /
Dumper, ladder / 2 M rule adherence
Excavation Self-Contained Breathing Apparatus, Shoring, Benching, Using shield, 1.5 M
Life Line - as needed depth Rule adherence / Proper entry
- exit route
Page 37 of 38

Approval
Figure: GENERAL LAYOUT
Page 38 of 38

Method Statement With Job Safety Analysis For Process Units Foundation Works (Rev 1) (13-08-2019)

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Method Statement With Job Safety Analysis For Process Units Foundation Works (Rev 1) (13-08-2019)

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Conex Petroleum Refining Company

Project Name 10,000 BPD PETROLEUM REFINERY AT FREE PORT MONROVIA

Site Contractor LUTECH ENGINEERING FZ LLC Issued For Review and

Document No. Rev. 1 Date 23/08/19