11.1 Scaffolding

SLN TANK REPAIR AND REPLACEMENTCONTRACT NO. C.1036806

SCAFFOLDING PROCEDURE

A 5 Oct 13 Issued for Comment Oni S

REV. DATE DESCRIPTION BY CHECK APPROVED APPROVED

TOTAL OR PARTIAL REPRODUCTION AND/OR UTILIZATION OF THIS DOCUMENT ARE FORBIDDENWITHOUT PRIOR WRITTEN AUTHORIZATION OF THE OWNER

DOCUMENT NO: 011-TMS-STRR-X-2013

CONTRACT NO:C.1036806

SLN TANK REPAIR AND REPLACEMENT

CONTRACTOR: PT. TIMAS SUPLINDO Page 2 of 16

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TABLE OF CONTENTS

1. OBJECTIVES...................................................................................................................................4

2. SCOPE....................................................................................................................................4

3. REFERENCE............................................................................................................................4

4. RESPONSIBILITY......................................................................................................................5

5. PROCEDURE...........................................................................................................................5

5.1. SCAFFOLDING MATERIAL..............................................................................................................55.2. TRAINING AND COMPETENCY REQUIREMENT....................................................................................6

5.2.1. Mandatory Scaffolding Training..........................................................................................65.3. TYPICAL SCAFFOLDING................................................................................................................6

5.3.1. Bracket Scaffolding...........................................................................................................75.3.2. Rolling Scaffold...............................................................................................................105.3.4 Pipe tube scaffolding…………………………………………………………………………………. 135.3.4 all Prevention / Protection Training........................................Error! Bookmark not defined.

5.4. SCAFFOLDING SAFETY...............................................................................................................14Appendix 1 – Detail Engineering Design & Calculation............................Error! Bookmark not defined.




1. OBJECTIVES

This procedure describes the minimum requirements and guidelines of working at heights and safe operations of ladders and scaffolding use in all Timas work activities.

These guidelines are to be used to provide minimum access and egress, safe working conditions and also maximum prevention / protection against falls from elevations. It is also meant to provide a minimum training standard to ensure that personnel understand and comply with the programme, thereby achieving 100% fall prevention / protection to all Timas Suplindo employees and sub-contractors exposed to a fall hazard.

2. SCOPE

2.1. This procedure is applicable for all scaffolding work activities within Timas Suplindo and its subcontractors during the execution of SLN Tank Repair & Replacement Project.

2.2. Contractor shall follow the Company’s Scaffolding Safety / Working at Height Safety process whenever working in the Company’s facilities.

3. REFERENCE

This procedure makes reference to the following document:

TIMAS Level 1 HSSE Management System (Doc. No: TS-HSSE-MSM-01)

TIMAS Level 2 HSSE Procedure for Scaffolding and Ladder Safety

Indonesian Occupational Safety Act No.1/1970

Indonesian Ministry of Manpower Decree No. PER.05/MEN/1996 – Health and Safety Management System (SMK3)

Internationally recognized standards i.e. ISO14001 and OHSAS18001

COMPANY HSSE Requirements as stipulated in the ITB Document / Contract.




4. RESPONSIBILITY

4.1. Senior management is responsible for supporting this scaffolding procedure and ensuring scaffolders are trained and use the procedure as an accident prevention tool.

4.2. Line supervisors, foremen, and leading hands are responsible for applying the procedure whenever they are build a scaffolding platform.

4.3. Employees are responsible for following the scaffolding procedure whenever they are working at height and comply with the minimum requirement of scaffolding procedure.

5. PROCEDURE

5.1. Scaffolding Material

All cases, access equipment, whether tube and fittings, proprietary systems or special equipment, shall be suitable in all respects for its intended application. For the majority of applications this will entail the use of steel tube, fittings and boards in accordance with table below. However, the use of proprietary systems manufactured from steel or aluminum or the use of special equipment shall be acceptable when the access is required for a short period only, or is required to be easily moveable and there is a firm footing.

All scaffolding components, i.e.: tubes, couplers to be used in Timas worksites shall be manufactured to a standard recognized and accepted in the industry and shall have the appropriate certification.

Standard Additional Requirement

Steel tube BS 1139 Parts 1 Only galvanized tube to be used. Tubes to be regularly inspected and cleaned. All tubes to be checked before use for corrosion and general condition. Defective tubes to be discarded. Butt welded tubes may be used on condition that the welding has been carried out to an approved procedure.

Fittings BS 1139 Parts 1 All fittings to be examined before use for damage and wear. Damaged or worn fittings to be discarded. No heat to be applied to fittings. Moving parts to be lubricated.

Boards BS 48 Where any hot work is to be carried out, boards shall be protected with a non-combustible covering which shall be laid and tied in such a way that it shall not constitute a tripping hazard.




5.2. Training and Competency Requirement

5.2.1. Mandatory Scaffolding Training

In addition to the general requirements for working at heights, the following requirements apply to scaffolding work.

All personnel employed for the purpose of erecting, modifying or dismantling scaffolding will meet the following requirements:

a) All scaffolding personnel (Scaffolders and scaffold Assessors/ Inspectors) who are assigned for the project has competency certificate from approved training provider.

b) The training course should be from recognized Training Organization such as the Manpower Department.

c) Scaffolding Course for Scaffolders.

d) Scaffolders who hold the training certificates are expected to be competent in erection and dismantling of scaffolds.

e) Scaffolding Inspection Course.

f) All scaffolding personnel shall complete a Contractor EHS Induction before start work at client or contractor location.

However the erection of proprietary system scaffold by unqualified personnel shall be an exception to the above requirement.

All personnel who supervise activities that include the use of scaffolding and access platforms, including all HSE Supervisors, shall complete the scaffolding training course as regulated in the Directorate General of Work Monitoring of Manpower Dept No Kep. 0/DJPKK/004 on Competency Certification in Construction OHS. Approved certifications are required.

5.3. Typical Scaffolding

Contractor has indentified any scaffolding work with the other method, it is used to ease erection of the tank. Several type scaffolding to be used during this project shall completed with engineering design, calculation, and NDT for every weld joint, its can be found in Appendix 1.

The following scaffolding method will be used during tanks erection:

5.3.1. Bracket Scaffolding




a) Bracket Straps

I. Bracket straps are normally located 52” down from the top of the sheet. The horizontal spacing between bracket straps is indicated for various tank diameters and board lengths. Bracket strap spacing must never exceed 10’ 6”. The number of bracket straps required for one shell ring with trapdoor is equal to one and half the number of boards plus 1. Use the arc dimension when laying out and attaching bracket straps on inside of the shell on the ground or the outside of the shell in the air. Use the chord dimension when laying out and attaching bracket straps on the inside of the shell in the air.

II. Make sure that the bracket straps fits tightly against the shell before tacking. Bracket straps can be adjusted by placing them against a shell plate and tapping them with a 4 lb. hammer.

III. Bracket straps are to be welded only by qualified welders – not tackers.

IV. Weld across the top of bracket straps as shown in Fig. 7.1.2a. Make all welds in the order and direction shown. Reverse the direction of welding on the ends of the welds to fill the crater. Use a 3/16” filled weld of E6010 or E7018 electrode (on material other than mild steel, use the electrode as specified in the welding procedure to weld the bracket to the structure.

V. If, for whatever reason, the welding of a bracket strap cannot be completed, it must be removed by breaking the attaching welds. Never leave a bracket strap that is partially welded.

VI. All welded bracket straps must be inspected by foreman, pusher, weld supervisor, or a qualified person designated by the foreman. The welder who welds the strap must not be the person that does the inspection. The slag must be removed from the weld before inspection. To show that the bracket strap weld has been inspected and correctly welded, it must be circled and initialed with lumber crayon by the person inspecting the weld.

VII. Bracket straps may be used a maximum of 2 times. If a bracket strap is being used a second time, turn it over and weld on the side which has not been welded on.




b) Scaffold Bracket

I. All brackets must be inspected carefully before starting to erect each structure. Items to look for include cuts, gouges, rusting, bent members, or pitting which weaken the strength of structural members. Look out for undersized or insufficient welding of the welded members, cracks in the welds or any field modifications made to standard brackets. Do Not Use Damaged Or Altered Brackets – mark them clearly (Red Tag) and return them to the warehouse or destroy them in field and report to warehouse.

II. Brackets are not to be welded on in the field. Do not strike arcs on brackets to light a torch or to adjust a welding machine. Do not make any alterations to brackets (or any other erection equipment) in the field without permission and detail drawings from the construction office.

III. Brackets must be installed plumb (vertically). Note that if a bracket is installed only 5” out of plumb, it will support only half of its designed load (see Fig. 7.1.2b). The maximum permissible load on a bracket is 1000 lbs.




c) Handrail Posts (Bracket Arms)

I. Handrail Posts (see Fig. 7.1.2c) are attached to the brackets to secure wire rope hand lines.

II. Hand rail Posts must be inspected before use similar to brackets. Check for corrosion and defective welding. Defective handrail posts should not be used.

III. Handrail Posts must be secured to the Bracket Arm Stubs on the bracket (or other support device) with a bent weld rod or pin.

IV. Handrail Posts are provided with a hook on the outside which may be used to support light objects such as key channels, scaffold brackets, etc., so they may be safely stored off of the scaffold.

d) Scaffold Platform (Toe board, Plank and Handrail)

I. All scaffolding must be built with edge protection.

II. Guardrails and mid rails must be supported at intervals not exceeding 1.8 meter, parallel with the platform and not more than 100mm outside the platform edge. The guardrail should be approximately one (1) meter above the platform with the mid rail positioned midway between the guardrail and the toe board.

III. Toe boards and kick plates should be at least as strong and as rigid as timber scaffold planks and be securely fixed. They should extend not less than 150mm above the platform surface. The gap between the platform and the toe board should not exceed 10mm.




5.3.2. Rolling Scaffold

Rolling scaffolds are supported on, and roll around, the shell. The most common of the rolling scaffolds used for tank shell erection are discussed below. Always use a safety belt hooked off to the rolling scaffold while climbing over the shell into a rolling scaffold. Whenever you are working more than 4 ft. above the bottom of the buggy, you must be either (1) boarded in such that there are no open spaces wider than 12”, or (2) hooked off.

Rolling Scaffold (Std. 2L11)

This is the most common shell buggy used in shell erection. It can be used as a portable scaffold either inside or outside (opposite side from the fixed scaffold) for welding vertical, round seams and fitting/welding stiffeners and wind girder (see Fig. 5.4.1).

Lightweight Rolling Scaffold (Std. 2L20)

This buggy is similar to the 2L11 rolling scaffold and is used as a portable scaffold (on the opposite side from the fixed scaffold). The main difference is that this buggy is narrower and does not have a removable section so it cannot fit around a windgirder. It is used for welding verts and round seams. It is used for welding verts and round seams (see Fig. 5.4.2).

Rolling Cage (Std. 2L22)

This is a short buggy that is used on the same side as the fixed scaffold to weld the upper portion of the vertical (see Fig. 5.4.3).

Folding Vert Buggy (Std. 2L22A)




This buggy is similar in size to the 2L20 buggy. It has pinned connections and folds flat for storage and transport. Unlike the 2L11 and L20 buggies, the Vert Buggy does not have a chain drive and must be pushed round the shell. It is used to weld verticals on the opposite side from the fixed scaffold (see Fig. 5.4.4).

Plugging Buggy (Std. 2L24) :

This buggy provides a portable scaffold below the fixed scaffold. It is used for removing bracket straps after the scaffold has been raised (see Fig. 5.4.5).

Fig. 5.4.1 Fig. 5.4.2

Fig. 5.4.4Fig. 5.4.3




Fig. 5.4.6Fig. 5.4.5




5.3.3 Pipe tube scaffoldingIs scaffolding erected with standard method. Timas will design movable scaffolding from material pipe tube to install / dismantle tank accessories.

- Approximate Maximum Total Load for Persons and Material Kg per platform per bay: Light duty 225kg Medium duty 450kg Heavy duty 675kg

-Mobile Scaffolding

.




5.4. Scaffolding Safety

Scaffolding operations in Timas Projects shall fully comply with the following requirements:

5.4.1. JSA must be completed and reviewed with all personnel involved with a work activity in erection, dismantling or utilising the scaffold.

5.4.2. Prior to erection, any necessary work permits shall be obtained. The operational and geographical parameters specified in the permit shall be fully complied with.

5.4.3. Prior to installation commencing a Scaffold Inspector/ Assessor/ Supervisor shall inspect:

a. The ground area upon which the scaffold is to be positioned.

b. All equipment which shall form any part of the scaffold staging means of access, work platform and lifting facilities.

c. If the inspection proves satisfactory, approval shall be given for scaffolding installation. Such approval shall be recorded in the site scaffold/ staging inspection log book.

5.4.4. For scaffolds after erection, and before work commences upon the scaffold, Scaffold inspector/assessor shall inspect and approve the scaffold and shall record this inspection in the site scaffold/ staging inspection log book.

5.4.5. Prior to work each day, a Scaffold Inspector/ Assessor/ Supervisor shall inspect all scaffolding, staging and peripheral equipment. Where any scaffold of staging is altered or adjusted in any way, it shall be inspected by the Scaffold Inspector/ Assessor/ Supervisor prior to work upon it re-commencing

5.4.6. Prefabricated scaffolding and any associated components shall be constructed and utilized in strict accordance with manufacturer’s instructions.

5.4.7. Scaffolds shall be constructed and dismantled under qualified supervisions. They should hold appropriate certificates.

5.4.8. Where any scaffold or staging is altered or adjusted in any way it shall be inspected and approved by the Scaffold Inspector/ Assessor/ Supervisor prior to work upon it re-commencing.

5.4.9. If unauthorized modifications are observed, they shall be reported to the supervisor and a “DO NOT USE” warning shall be displayed




5.4.10. Preliminary study of erection methods shall be conducted by Scaffolding Supervisor prior toerection. This is to reduce erection time; subsequent use of maintenance purposes, of the facilities set up for erection, and reduces hazards to workers

5.4.11. The studies shall cover at least overall erection and assembly design, detail engineering andworking methods for installation and removal of construction aids and safety features. (Scaffolding exceeding 40 meters and above in height and overhang etc., must have a Professional engineers drawing and approval before the commencement of work).

5.4.12. A scaffolding log book shall be completed and maintained by Scaffolding Supervisor.

5.4.13. The Scaffolding Supervisor should conduct routine check of the content and quality of information in the log book.

5.4.14. The footing or anchorage for scaffold shall be level, rigid, and capable of carrying the maximum intended load without settling or displacement (includes base plates, support etc). Unstable objects such as barrel, boxes, loose bricks or concrete blocks, shall not be used as platforms, or to support scaffolds or planks.

5.4.15. Any scaffold, including accessories such as braces, brackets, trusses, screw legs, ladders, etc, that are damaged or weakened shall be immediately replaced. Scaffold planks shall be free of cracks, splits, excessive knots, or notable damage. Damaged plank shall be destroyed.

5.4.16. All working platforms ie., scaffolding planks shall be secured to the scaffold frame before access is granted to the workers. Scaffolding is secured using steel wire of scaffold plank clips(Tie backs)

5.4.17. Scaffolding activity should be discontinued during adverse weather conditions (i.e. thunder, lightning heavy rain and strong wind).

5.4.18. Ladder access shall be provided, and made secure at every working platform level.

MEANS: Ready

Scaffolding

Safe Scaffolding

MEANS: Not Safe

Scaffolding Under

Construction/Repair

Do Not Use




5.4.19. Scaffold tubes and fittings or the integral parts there of shall not be considered as access.

5.4.20. All access ways and areas to scaffold shall be kept free of all debris and construction materials in order to provide safe entry/ exit.

5.4.21. Materials, tool, equipment, etc, shall not be thrown up to a higher level nor down to a lower level and shall not be carried by a person if it affects the safety of his own movement to a higher or lower level. Fiber rope should be used to raise and lower materials.

5.4.22. Metal ladders or scaffolding shall not be used in the vicinity of any electrified conductor or equipment where there is a possibility of a person receiving an electric shock unless the equipment has been adequately isolated or insulated.

5.4.23. Ladders shall be secured.

Documents

11.1 Scaffolding