FABRICATION PROCEDURE

TABLE OF CONTENTS

1.1 PURPOSE

1.2 SCOPE

1.3 REFERENCES

1.4 TOOLS & EQUIPMENTS

1.5 MATERIALS

1.6 PRELIMINARY

1.7 QUALITY CONTROL

1.8 HEALTH, SAFETY & ENVIRONMENT

1.9 WASTE MANGEMENT

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1. PURPOSE

The Purpose of this Fabrication Procedure is to describe the method to be followed in detail,
identification of hazards and elimination of the same for Fabrication Supply and Installation of
Steel Structure and Metal Works while ensuring all related activities within the project scope of
work are carried out safely, Project Specification, approved shop drawings and project procedures.

2. SCOPE
Project Name: Package East - Wadi Safar - Riyadh

Site Location: Riyadh, KSA

Contractor: RTCC

This Method statement will describe the methodology to execute the Steel Structure
and Metal Works, as per approved Shop drawing, project specifications and Material
submittals.

3. REFERENCES
a. Issued For Construction Drawings.
b. Project Specification
c. Approved Material submittals
d. PQD
e. Project HSE Plan.
f. Approved Shop drawing

4. TOOLS & EQUIPMENTS

DESCRIPTION QUANTITY DESCRIPTION QUANTITY

Survey Equipment (Total Station) As required Survey Equipment (Level) As required

Grinder As required Drilling Machine As required

Right Angle As required Spirit, Bar level & Water level As required

Chisel/Hammer As required Measuring Tape/Plumb As required

Cutting machine As required Hammer As required

Air compressor As required Protection Materials As required

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Chain blocks As required Man lift / Scissor Lift /Cranes As required

Scaffolding As required Welding Machine As required

Note- Equipment schedule will be followed/provided as per approved program.

5. MATERIALS

❖ Steel Structure & Metal Works

6. PRELIMINARY
6.1 PRE-REQUISITES
• Procurement of material
• Storage of material
• Fabrication of material
• Delivery of material to site
• Permit to Work.
• Approved Shop Drawings.
• Approved MEP Coordination Drawings & MEP Clearances.
• Approved Material delivered, Inspected and available at Site

6.2 PROCUREMENT OF MATERIAL

• All Materials will be procured from approved supplier from procurement department.
All Steel material which are approved along with material submittal and shop
drawing will be used, test certificate submitted with the sample, that included all the
material details, physical & chemical properties etc.

6.3 STORAGE AND PROTECTION OF RAW MATERIAL

• All Steel Members shall be unloaded with care to avoid fall. Proper Material
Handling equipment (Crane mounted truck Or Forklift) will be use transportation
and unloading of the material. Material shall not be allowed to fall from stack and
shall be wedged to prevent further movement. Materials shall not be stored in such
a manner as to impede traffic or obstruct access, every precaution to be taken to
preserve their cleanliness before fabrication.
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6.4 FABRICATION
• All Fabrication will take place as per approved shop drawing in accordance with
actual site condition.
• Steel tube members will be cut to size using Cutting machine.
• Plates will be cut to size as per approved shop drawing using plasma cutting
machine.
• Drilling holes in plates will take place in the hole punching machine and Pedestal
• Drilling Machine as per size of the hole.
• After all the members are cut and drilled, they will be thoroughly cleaned for any
burrs in the edges.
• All the sharp edges from all the cut portions will be chamfered and rounded to avoid
any injury during further fabrication and installation.
• Then we shall fabricate the Steel Fence as per approved shop drawing.

6.5 WELDING

• All the welding work are done as per approved shop drawing. For avoid the distortion
in the welding consider stiffeners on one side while welding. After the welding chip
the all-welding flux and clean with wire brush. Grind the porous, cracked or
incomplete penetrated area properly and weld again. Special precaution will be taken
to grind the weld portion so that no welding slag can be accumulated with the
welding material in the subsequent welding.
• This will prevent any possible blow hole in the weld.
• After finishing all the welding, we will again grind all the welds to work out slag and
remove sharp points.
• After complete fabrication internal QA/QC will check the fabricated material.
• Once QC check is passed, All the fabricated material will be sent to painting section
yard for Epoxy painting.

6.6 PAINTING

6.6.1 Surface Preparation

• The Substrate must be sound clean dry free from dust, oil, grease and laitance etc.
from well cured and dry concentrate /plaster surface, manually with rubbing stone,
scrapper and sand paper etc.

6.6.2 Sand Blasting (If required)

• In this method, dry abrasive is propelled against the surface to be cleaned so that
rust, contaminates, are removed by the impact of the abrasive particles. Moreover,
the surface must be cleaned of blasting residue before painting. This is usually done
by blowing clean air across the surfaces.
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6.6.3 Application of Primer Coat

• The Prepared substrate should then be primed with solvent free primer using a spray
machine.
• Before application of the primer, ensure that the moisture content in steel is not
present, It should be dry.
• The primer should be thoroughly mixed in full accordance with the product data
sheet ( a slow speed drill with mixing paddle recommended for mixing) and applied to
the prepared substrate at the thickness of 100 microns dft.
• The respective technical data sheet should be referred for information like pot life, re
coating interval etc. which should be adhered to strictly.
• The primer should be allowed to dry for about 15 hours.

6.6.4 Application of Top Coating

• After drying of the primer, apply the first coat coating airless painting machine
• The Coating should be applied evenly over the surface to ensure a regular film
thickness of 150 -180 microns DFT.
• The Coating should then be spiked to remove any entrapment of air in the coating.

6.7 HANDLING AND STORAGE OF MATERIAL

• Deliver and store the Roof Canopy Steel Structure in factory packaging.
• The Roof Canopy Steel Structure materials must be categorized and stored to easily
retrieve for use in the areas as per work sequence.
• The materials must be stored properly to avoid damage, and must be stored in the
conditions as recommended by the manufacturer.
• Moving of the materials from the store to site must be done in accordance with
manufacturer’s recommendation and by trained personnel.
• The accessories to be used in the installation of the Roof Canopy Steel Structure must
be properly stored.

7. QUALITY CONTROL

• Work shall be executed as per the project specifications, approved shop drawings and
approve method statement/ITP.
• Steel Structure and metal works delivered to site as per the material submittal and
subject for approval prior to use.
• All workmanship shall comply with the approved mock-up, to maintain the quality
work shall be executed by the competent skilled worker, supervisor/foreman.

8. HEALTH SAFETY AND ENVIRONMENT

• All necessary PPEs such as helmet, High Visibility Jacket, Safety Shoes, Gloves,
Goggles, rubber boots and Safety Harness will be used by the personnel as applicable.
• Safe access will be prepared as necessary. The Safety Officer must check and confirm
before using.
• All unnecessary material on site that may cause accident will be removed.
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• Proper housekeeping will be done on regular basis before and after the completion of
work.
• Workers shall be provided with hearing protectors while working with equipment
that produce noise between 80 dB(A) - 85 dB(A) when they ask for them.
• Workers must wear hearing protectors while working with equipment that produce
noise 85 dB(A) or above. The hearing protectors must be selected, so as to eliminate
the risk to hearing or reduce it to as low a level as is reasonably practicable.
• All Electrical equipment and power tools shall be color coded.
• HSE shall assure the competence of the workers using the power tools by training
them before they start their work.
• All the workers must be aware of the Evacuation and Emergency Response
procedures.
• Competent supervisor will always be at work locations.
• All workers involved in this activity shall be giving awareness training on COSHH
handling by the HSE Department before commencement of work activity.
• Specific PPE/RPE to be followed as MSDS and COSHH Assessment.

9. WASTE MANAGEMENT
❖ Wastes generated during the activities will be segregated during the job and will
be collected at different locations. All the segregated wastes will be disposed in
approved locations by approved third party contractor.