PE design and calculation

Fabrication & shop drawings

Machinery (i.e forklift, boom lift, mobile crane, welding machine etc provide breakdown)
Transportation to site
Hot-dipped galvanised
Accomodation
1.0 Introduction

This document shall address the typical works for KM6 level 3 MDC iVE - PB Project.
This method statement will serve as guideline to carry out and complete the fabrication
and installation work for steel structure in construction activity. The detail of this
proposal includes type of Plants and machinery, sequence/area of works, inspection
(Quality Control) and Safety.
The Construction standard above is shown as following IMCS Specification:-

IMCS Description
Section 05_50_00_00(05500) Metal Fabrications
Section 03_15_10_00(03151) Anchor Bolts and Inserts
Section 05_12_00_00(05120) Structural Steel Framing
Section 09_91_13_00(09915) Painting Building
Section 01_81_13_00(01913) Sustainable Design Requirements.

2.0 Resources

2.1 Materials

All materials used on site must be approved type and they are as follows: -

No Type / Brand Name Description of Materials

1 Electrode welding rod Electrode with grade MS 6014 &
7016 & 7018
Flux Core Wire Kiswel K - 71T 1.2 MM Ø
filler wire)
2 Bolt & Nut M16, Mild Steel with Grade 8.8
3 C-channel Steel Structure 152 X 76 x 18 kg/m
4 Rectangular Hollow Sections, RHS 50 X 50 X 4.0mm Thk
5 M.S Plate 175 X 250 X 20mm Thk
6 Anti Sag Rd 12 MM
7 SikaGrout 215 Grouting
8 Hilti Re - 500 V3 Injection Adhesive / Grout
9 NIPPON ZINC PHOSPHATE PRIMER Primer Coat Alkyd rust inhibitive
primer, 1.1 MDFT
10 Layers of external NIPPON 9000 Finish Coat / 3.0- 5.0 MDFTPC /
GLOSS PAINT ( lavender Grey 1307) 152.4 micron

2.2 Machinery and Equipment

No Type / Brand Name Quantity

1. Survey and levelling 1
2. Hand tools, measuring tapes & etc. 1
 3. Survey and leveling Equipment 1
4. Fire Extinguisher 1
5. Forklift (1 ton or above) 1
6. Drilling machine 2
7. Pallet Truck 1
8. Paint Equipment (Roller, Brush and 4
Spray)
9. Industrial Extension Socket (Portable) 1
10. Spot Light 1
11. Scaffolding Set
12. Grinder 1
13. Portable Exhaust Fan with Filter 2
14. Welding machines 1
15. Barricade Cone 6
16. Boom Lift 1
17. Mobile Crane 50T 1
18. Lorry/ Trailer 1
19. Lifting Belt (2-6 Tonne Capacity) 4
20. Shackle (8.5 Tonne Capacity) 4
21. Mobile Platform 10 Tonne Capacity 1
22. Guide Ropes/ Guidelines (30m) 1
23. All other lifting gears As per site requirement

2.3 Manpower Involved / Plan

Designation / Name Key Person Quantity

Manager: Kenny ✓ 1
Engineer: Azizul ✓ 1
Supervisor: Zaki ✓ 1
EHS: Ramu ✓ 1
QA/QC: Azleen ✓ 1

2.4 Contractor Involved

Company Designation/ Name Quantity

HKL ENGINEERING SOLUTION PIC / LIM CHIN WEE 1
SDN BHD Worker 7
Chasen Logistics Sdn Bhd PIC/ Raja 1
Lifting Supervisor
Crew 4
2.5 Qualification

Position Qualification Quantity

Welder 2G WQT 3 nos
Operator Competent Crane Operator (JKKP) 1
Lifting Supervisor Competent Lifting Supervisor (CIDB) 1
Rigger & Competent Rigger & Signalman (CIDB) 4
Signalman
Forklift Competent Forklift Operator 1

3.0 Primary Requirement

3.1 Coordination Requirement

i. The mobilizing operation shall be led by an Engineer. The role &

 responsibilities of the various parties involved in the operation and
together with the line of communication are shown in the organization
chart.
ii. All tools, equipment and machinery will be brought in to the site are
well inspected properly and placed in proper order at the designated
storage area prior to commencement of work

iii. Client shall be informed of the date and time of installation works.
iv. The EHS officer shall determine the condition permissive for the
operation before proceeding with work.
v. All installation activities shall follow the approved installation
procedures and any change made prior to or during the operation
shall be agreed upon by at relevant parties.

3.2 Other Operation Requirement

The following area to be prepared and performed during installation works.

i. Site Incident Prevention Plan (SIPP) for any works to be perform at

Intel.
ii. Pre-Task Plan (PTP) to be filled daily before starting any works.
iii. To attend Toolbox Meeting every morning prior to start works.
iv. To wear necessary PPE’s as per safety requirements (i.e., safety
goggle, safety shoes, safety helmet & so on)
v. Partly erected/dismantled scaffold must have suitable warning signs
posted in prominent locations, be barricaded off, or policed to
prevent unauthorized [Link] use of Scaffold tags is strongly
recommended.

3.3 Receiving
i. All equipment/tool delivery to site shall be informed in advance to
Kinetics management team.
ii. All materials receive at the site shall be visually inspect by site
supervisor/ engineer for any damage after unloading. Any damage
shall be taken immediately, if possible to avoid any delay of erection.
iii. Inspection for delivery on site shall be carry out the inspection
together with KINETIC QAQC & Client Representative for proper
checking before used it.

3.4 Handling
i. Person in charge or site supervisor to closely monitor the workers
involved in dismantle and installation work to ensure compliance with
safety and quality requirement onsite.
ii. Work shall be done in proper manner to prevent damage equipment
as well as the surrounding work area.
iii. Personnel handling the materials must wear gloves.
iv. Transfer the items collected to the designated demolish area.
v. Work in pairs to transfer material or heavy items.

3.5 Storage
i. The materials deliver on site shall be place at storage area. The
materials shall be group, barricade and put proper barrier ownership
tag if necessary
 ii. Materials are to be store in stillages and on pallets as appropriate in
a manner that prevent damage.
iii. Structure shall be supported by wood to avoid from any
starches/unlevel.
iv. Housekeeping at the end of the day.

4.0 Work Activity Methodology / Arrangement

4.1 Site Preparation

I. Site clearing.
II. Barricade work area complete with signage and polytent.
III. Perform pre-post checklist and get the approval from EHS and Intel
PM.

4.2 Mobilization & Installation

No Activity Sequence
1 a) To inform related Project Manager, System Owner and KINETICS EHS
management before start work for the day.
b) To obtain the entire relevant valid EHS document before start work.
c) To assign all the workers, stuff to attend safety induction before start work.
d) Get the valid permit for the workers and machinery to enter the site.

2 a) Identify area to be worked on. Work shall be carried out according to

drawings
b) Inform the Project Manager or person in charge before start work.
c) Detail of the activity to be performed shall be informed/briefed and
explained before starting work.
d) Precautions must be taken before and during activity in accordance to
DOSH standard.
e) During the progress of activity, the work shall be under the continuous
supervision of an experienced foreman.
f) Provide safeguards, including related signages, barricades, temporary
fences and other similar items that are required for protection of all
personnel during all activity involved.

3 Mobilization of tools and workers

a) To inform related Project Manager, System Owner and EHS Management

before start work for the day.
b) Obtained the entire relevant valid EHS document before start work.
c) Shall be use manpower to mobilize the materials into the work location and
storage area.
d) Get advised from KINETICS project management team for the location for
 material storage.
e) Shall be used forklift to mobilize the materials into the work area if
necessary.

4 To brief the workers on the job sequence and streamline their job for hazard
avoidance prior work starts.

5
Work Sequences

Fabrication Steel Structural (Off Site)

a) Fabrication of all steel structural shall be studied properly according to

construction drawings details and specifications

b) Shop drawing where required will be submitted prior to commencement of

the work to enable fabrication of components.

c) All respective parties shall be visit site for taking actual measurement of all
the steel structural measurement and dimension before fabrication to be
carried out (Filter).

d) If any obstruction/suitability issues arises to follow the original

design/drawing, all the information shall be informed directly to respective
parties and will be follow-up with a new shop drawings for approval
with/without design calculation (if needed)

e) Qualified welder shall carry out welding works and welder performance
qualification shall be submit to KSM.

f) Visual inspection will have carried out and upon request by consultant the
testing shall be carried out testing using Ultrasonic testing and magnetic
particle inspection.

Cutting

Each steel structure will be properly cut into size (to be follow with Final
Approved Design/Drawing) by Qualified and Approved Steel Fabricator using a
Good Machinery/Equipment.

Jointing

Each joints shall be weld by a Qualified and Approved Welder(s).

Bolt Positioning

Each bolt position at the steel structure shall be marked properly and
accordingly and shall be double check before drilling process by [Link] of
bolt position will be carried out using a suitable tool(s). Holes shall be 1/16 inch
larger than the nominal bolt diameter, Holes for cast-in-place column base
anchor bolts shall be a minimum of 5/16 inch larger than the nominal bolt
diameter and fitted with plate washers unless otherwise shown on the Drawings

Making Good Treatment

 Any astatic defect(s) to the welded surface, drilled holes and etc will be properly

cured using a suitable method accordingly before received sand blasting layer.

Steel painting

Surface Preparation

Steel Structure Painting Council (SSPC)

a) Before any surface preparation is commenced, the surface shall be

completely dry and free from burrs, weld spatter, flux, loose scale, dirt, oil,

grease and any other foreign matter.

SSPC-SP2 Hand Tool Cleaning and SSPC-SP3 Power Tools Cleaning

a) SSPC-SP2 method use impact hand tools to remove stratified rust (Rust
Scale)
b) Use hand wire brushing, hand abrading, hand scraping or other non impact
methods to remove all loose mil scale, all loose or non adherent rust and all
lost paint.
c) SSPC-SP3 is power tool cleaning, which is a method of surface preparation
on steel surfaces with the use of power assisted hand [Link] use power
tools or blast cleaning as a substitute cleaning method (Brush grinder)

General Note(s)

a) SSPC -SP2 and SSPC-SP3 shall be performed after fabrication complete.

b) Primer Coat Nippon Zinc Phosphate shall be apply on the I-beam after cleaning
is complete done.
c) Allow minimum 16 hour for curing before apply finish coat.
d) Primer coat (Alkyd rust inhibitive primer, 1.1 MDFT) shall be test again on the
micron mm before or after the I-beam delivery on site. (Primer Coat 55-85
microns) Shall carry out inspection together with Kinetics QAQC for the primer
coat thickness test.

Pre-coat Checks

a) All visible oil grease and soil shall be removed with an approved materials the

cleaned area shall than be washed in clean chloride free potable water and

allowed to dry.

Paint Mixing

a) Paint shall be mixed thoroughly immediately prior to application mixing ratio

 set by the paint manufacturer shall be adhered to, recommended mixers
are mechanical stirrers paddle mixers and can vibrators or shakers. If
mechanical aids are not available mixing by hand is acceptable provided
the following procedure is employed.

b) For single packaged ready mixed materials remove a portion of liquid from
the top of the container and transfer to a clean container. Mix the remaining
portion with a clean broad strong [Link] a lifting whirling motion to
thoroughly incorporate the heavier liquid that has settled to the bottom
replace the removed portion a little at a time mixing thoroughly each time a
portion is added until the entire contents are of a uniform consistency a
boxing procedure (pouring back and forth several times to clean containers)
will assist in thorough mixing.

c) For multi –component materials multi –component material shall be mixed

in the volumes provided by the coating manufacturer. Kits shall not be
broken or split without the written approval of contractor. Each component if
pigmented, shall be mixed individually before combining them in the exact
proportions

d) Paint shall be thinned in accordance with the manufacturer’s instructions or

as called for in the project specification only thinners of a type
recommended by the paint manufacturer shall be used. Thinners shall only
be added under supervision and shall be thoroughly mixed into the paint.
The amount of thinner used shall be measured not estimated and the
percentage thinner used shall be calculated and recorded.

Painting

e) The representative of the paint manufacturer should visit the site at regular
intervals to provide technical support and shall submit a periodic report to
subcontractor /contractor confirming that painting is being carried out in
accordance with the requirements and quality of work is acceptable. An
adhesion test may be carried out if necessary.
f) The specific paint systems that shall be used are identified in the project
specifications. Application of all coating systems shall be in accordance with
the manufacturer’s instructions MSDS data sheets and project
requirements.

Primer Coat (Before Steel Structure Erection)-Off-site

Primer Coat Application

a) Primer coat application shall be as per project specification and product

b) manufacturer’s recommendation / data sheets.
c) Prior to application of primer all difficult to coat areas such as corners edges
d) and welds shall be stripe coated with the specified primer.
e) When zinc primer is used, checks for surface zinc oxide formation shall be
made immediately prior to applying an epoxy topcoat. Any oxide formation
shall be removed either by high pressure cleaning with potable water or
hosing with potable water and then scrubbing with a soft brush to remove
all the zinc salts. The surface shall be thoroughly dried before applying the
top coat.
f) Dry film thickness readings will be taken and calculated as per project
specification and shall be recorded on the inspection record this applies to
each individual coat to control the final thickness of the coats the QC
inspector may use WFT (wet film thickness ) measurements as an indicator
for final thickness.

Intermediate and Finish Coat (After Steel Structure Erection)-On-site

General Note(s)

a) After the I-beam is being install and positioning, 2 layer of finish coat shall
be
b) apply on the i-beam by using Nippon Paint (Nippon Paint 9000 Gloss Finish
- Lavender Grey-1307).
c) Allow minimum 8 hour for curing before apply finish coat.
d) Total 2 layer of finish coat shall be at least Around 30 - 35 µm per coat.
Shall carry out inspection together with Kinetics QAQC for the primer coat
thickness test.

Intermediate and Finish Coat Application

a) The paint coats shall be applied as per project specifications and product
manufacturer’s recommendations /data sheets.
b) No mixing of different manufacturers coating in any system is permitted.
Only approved paint manufacturer products shall be applied.
c) Paint shall be applied by one or a combination of the following methods.

i- Brushing

ii- Roller coating

iii- Airless Spraying

d) The method of application of coating shall also be governed by project

specifications.
e) Before application of intermediate coat the required primer paint touch up
will be applied if any paint damage.
f) Each coat shall be checked for correct average DFT by the QC or prior to
application of subsequent coat.
g) Surfaces shall not be re coated until the preceding coat has properly dried
h) cured. The surface may be considered ready for re-coating when the next
coat
i) can be applied without the development of paint film irregularities such as
 lifting
j) or loss of adhesion of the undercoat. However the minimum or maximum
drying or curing time specified by the paint manufacturer shall be the
acceptable.
k) Re-coat period paint shall not be force dried so as to cause checking,
wrinkling, blistering, pores formation or any condition detrimental to its
appearance. Newly painted surface shall be protected to the fullest extent
feasible from rain condensation, contamination snow and freezing until the
coating has dried.
l) Preferably successive coats of paint should be of different colors however if
they are of the same color alternate coats shall be tinted to produce
sufficient contrast to ensure complete coverage of the surface .The final
finish coat shall not be tinted. Tinting material shall be compatible with the
paint and shall not be detrimental to its service life.
m) Where the specified dry film thickness is not achieved additional coats shall
be applied until the required thickness is obtained application shall be such
that the film thickness will not affect the appearance or service life of the
paint.
n) All paint shall be applied either by air spray or airless spray as specified by
paint manufacturer’s. The use or brushes is only allowed in the case of
repairs or in difficult areas where spray technique is not practical.
o) All paint shall be applied a workman like manner. The finished application
shall be uniform in color texture and appearance .The work shall be free of
sags wrinkles and excessive brush or roller marks any deficiencies shall be
corrected.

RC STEEL STRUCTURE INSTALLATION

a) Steel member will be inspect at factory for MRI, all steel structure will paint
on spot after fabrication at factory, materials will deliver and direct install on
site step by step and part by part. The complete fabrications steel member
(Pipe bridge) as provide in approve shop drawing.

b) Skill worker to mark the bolt location on the RC steel structure and beam by
laser or measurement tape to confirm the setting out point is accurate.

c) Bolt will install after RC beam, skill worker to drill the RC steel structure
after confirmation setting out with QAQC and plant bolt for steel structure
with approval epoxy chemical (Hilti RE-500).

d) Bolt need to protect by masking tape to prevent damage during work if

necessary.

e) Always check the alignment and tighten for bolt and nut to prevent from
rocking.

f) Site worker must always double check the position, alignment and
installation based on approval shop drawing

g) Bolt will plant to concreted roof beam by Hilti RE-500 after setting out
confirm by QAQC KSM, scissor lift or boom lift will be used for external area
 installation.

h) Touch up to all damage surface with approved paint materials after steel
structure complete install to position.

Inspection of Member

a) Inspect members for damage due mishandling or careless storage.

b) Make sure each member is placed in its proper position in the structure and
that fillers, shims, and washers required for the type of connection are
properly used.

c) Prevent abuse of material by bending, straining or heavy pounding by

sludge.

d) Inspect the accuracy of match-marked connections.

e) Check the painting work.

f) After finished the painting work, all steel member shall be checked that the
small area is painted.

Pre-assembly and Erection

a) All materials shall be place on designated area near the location for
assembly and erection.
b) Surface steel structural member shall be clean by air blowing on ground
prior for lifting works.
c) Provide dunnage underneath to avoid materials on direct contact with soil
and protect from dirt.
d) After pre-assembly check if the bolts are already snug tight condition by
using torque wrench. Mark the as applicable.
e) Lifting of painted structural shall be done with nonabrasive chocker.
f) The crane is responsible for loading or unloading structural members shall
be assigned separately prior to erection works.
g) Position the cranes on designated area. Crane 1 shall be responsible for
the pre-assembly of column and girders in ground level and assisting crane
2 for erecting frame assembly. Crane 2 shall be responsible for the erection
of frame assembly from ground level to its designated location and assisting
erection girders connection frames. Crane 3 or Boom lift shall be
responsible for the erection of girders connection to erected frames, tie
beam and bracings.
h) The ground where the crane will be position shall be stabilized. Clearance
or the crane access way shall establish and maintained the duration of
works.

Bolt Tightening

a) After QC inspection and acceptance of pre-alignment records, bolt tightening

shall be done at all grid lines. After check tightening need be marking.
 Cutting Steel Member using Oxy Cutting

The Pipe Bridge are modified by cutting the RHS steel member to follow the
dimension as mentioned in approval drawing (to be follow with Final Approved
Design/Drawing) by using Oxy Cutting processes.

Welding works

a) The welding for RHS steel members to follow the new dimension shall be
performed in accordance.
b) Welder shall have valid qualification which have been certified by means of job
clearance card performance qualification of contract welder and certification
review and registration of project welder.
c)

Touch-up application

a) As mentioned in spec, when damaged painting on surface on steel

structure is observed, and the unpainted area by masking at connection is
exposed, surface shall be touch-up.

b) All repaired, reworked, damaged steel support be coated as per applicable

coating system schedule.

4. BOOM LIFT

a) Inspect the boom lift before use. Inspect any of the hydraulic hoses and
fittings for leaks. Check the air pressure in the tires.

b) Start the boom lift with no person in the basket. Operate the control panel
from the ground, checking to see that every function is in good working
order. Switch the active input to platform so you can operate the boom lift
from the basket.

c) Strap on a safety harness. When in the basket, latch the attachment of your
safety harness onto the proper attachment in the basket.

d) Examine the area around you and check for any potential hazards, such as
downed power lines, loose soil or any other obstacles. Also be sure you
steer clear of power lines as an overhead hazard.

e) Steer your boom lift into the target area, again making sure you steer clear
of any sudden hazards. Adjust the angles and height of your boom arms
accordingly. If working in a rather tight area, retracting arms in the reverse
order in which extended is an easy way to get out.

f) Perform the work required and lower the boom lift to its locked position.
Bring the arms low enough to the point where can safely exit the basket.
 Shut down the boom lift at the ground.

5. GENERAL LIFTING WORK FOR INSTALLATION

The crane is responsible for loading or unloading structural members shall be

assigned separately prior to erection works.

a) Preparation of parking crane are as indicate in lifting plan

b) Observe for the safe access and egress of the crane into the site
c) Check and follow the lifting plan for crane position to lift, swing and
released the load.
d) Conducted TBM before lifting operation start, all personnel involved will
be brief on the determine lifting plan and all safety aspect.
e) Barricade the area of the lifting operation, informed to other site
personnel the dangers of working in the vicinity of any moving load and
the crane.
f) Closely Monitor and examine for obstructions, particularly plinths or any
obstruction to the safe positioning of crane’s outriggers
g) Outrigger steel plate will be positioned under outriggers. The hydraulic
outriggers will be extended over mats and the crane levelled. The
crane's boom will be raised and telescoped to the required length.
(Based on approve lifting plan)
h) Once arrived, material trailer/lorry will be escort by traffic controller
(flagman) into the unloading area as indicated in lifting plan.
i) Material arrived will be check (DO) before it can be unloaded into the
required position. (Loading platform)
j) The sequence of rigging will follow the manufacturer's
recommendations, which will be strictly adhered to all times.
k) The rigger will attach chain/web sling from crane hook block to the
material lifting point and making sure it secured before lift.
l) Guide ropes/Tag lines will be attached to prevent the swinging of the
load. Once it is confirmed by the rigger that the load is level, the lift will
commence to the required position under the strict guidance of the
signalman.
m) Appointed signalman will control the crane movement and lifting
operation.
n) Ensure that loading platform area is clear where the load is going to be
offloaded.
o) All workers shall always remain clear of the load until the load is at waist
level.
p) Release lifting tackle, hoist clear and repeat until complete.

6. DEMOBILIZATION

On the accomplishment of lifting operations, the crane's boom will be lower and
telescoped to the save length. The hydraulic outriggers will be shortened to save
length, outrigger plate/ timbers will be kept secure to the crane. Other lifting
equipment will be removed safely and stored properly. The crane and trailer/lorry
will be escorted to leave the site by traffic controller to the exit guardhouse.