[03571] method statement for installation of steel structure

421/422-SBG-CCM-010-00

The Construction Manager: The Contractor:

King Abdulaziz International Airport Development Project(J-10-421-PF-00 and J-10-422-PF-00)

Compliance with CM Comments

Sl.No.

1

Contractor's Reply

Saudi Binladin Group

Facility Code:

Area of Appliacation:

4Rev.MST For Steel Structure Installation (421-DCS-MST-S-00850) F100

F100-PTB

Submittal Tittle:

Sub-Contractor :

A separate logistic plan for zone A&E will be submitted with coordination with the main contractor.

Please find section 13 Survey scheme.

CM Comments

Logistics of access to the working areas.

Method of lining and leveling required.2

THE ENGINEER:

King Abdulaziz International Airport Development Project

(Phase I) Jeddah, KSA

THE CONTRACTOR:

Contractor: Saudi Binladin Group Doc. Ref. No.: 421-DCS-MST-S-00850 Rev.04 Contract No.: J-10-421-PF-0 Date Issued: 31 Jan 2013

Method Statement for Installation of Steel Structure

Page 2 of 82

List of Contents 1 Preface ................................................................................................................... 4 2 Scope of Work ........................................................................................................ 5

2.1 Pier .................................................................................................................................................. 5 2.2 Terminal Processor ....................................................................................................................... 5 2.3 International Hub ........................................................................................................................... 8 2.4 Boarding Bridge ............................................................................................................................ 9 2.5 Reference Standards: ................................................................................................................ 10

3 Personnel Roles and Responsibilities ............................................................... 10 4 General Construction Introduction .................................................................... 10

4.1 Schedules .................................................................................................................................... 10 4.2 Site Plan ....................................................................................................................................... 10 4.3 Manpower plan .............................................................................................................................. 11 4.4Mechanical and Equipment............................................................................................................. 11 4.5 General Work Procedures .............................................................................................................. 12

5 AESS requirement ................................................................................................ 14 6 Site Welding ......................................................................................................... 15 7 Bolting Tightening ............................................................................................... 15 8 Touch Up Painting Procedure ............................................................................. 15 9 Installation Method for Pier ................................................................................. 17

9.1 Shipping Unit ............................................................................................................................... 17 9.2 Erection Units .............................................................................................................................. 18 9.3 Detailed Erection Unit and weight ............................................................................................ 18 9.4 Crane Analysis and Selection ................................................................................................... 20 9.5 Temporary Supports ................................................................................................................... 24 9.6 Detail erection method ............................................................................................................... 25

10 Erection Method for Terminal Processor ......................................................... 34 10.1 Shipping units ............................................................................................................................ 34 10.2 Erection Weight and Selection of Cranes ............................................................................. 35 10.3Temporary support ..................................................................................................................... 38 10.4 Detailed Erection Method for Terminal Processor ............................................................... 39

11 Erection Method for International Hub ............................................................. 44 11.1 Shipping Unit ............................................................................................................................. 44 11.2 Erection Units ............................................................................................................................ 45 11.3 Erection Weight and Crane Analysis ...................................................................................... 48

THE ENGINEER:



THE CONTRACTOR:

Contractor: Saudi Binladin Group Doc. Ref. No.: 421-DCS-MST-S-00850 Rev.04 Contract No.: J-10-421-PF-0 Date Issued: 31 Jan 2013


Page 3 of 82

11.4 Temporary supporting ............................................................................................................... 56 11.5 Detailed Erection Method for International Hub ................................................................... 57

12 Erection Method for Boarding Bridge .............................................................. 62 12.1 General Dimension ................................................................................................................... 62 12.2 Transportation Units ................................................................................................................. 63 12.3 Erection Units ............................................................................................................................ 64 12.4 Crane Selection ........................................................................................................................ 64 12.5 Erection Method ........................................................................................................................ 65

13 survey schemes ................................................................................................. 66 13.1 Analysis of difficulties ............................................................................................................... 66 13.2 Survey idea and control method ............................................................................................. 67 13.3 Accuracy control of anchor bolts ............................................................................................ 67 13.4 Accuracy control of Zone A Banana trusses ......................................................................... 68 13.5 Installation position for banana truss ..................................................................................... 69 13.6 Positioning accuracy of PIER ................................................................................................. 69 13.7 Assembly and installation surveying for boarding bridge ................................................... 78

14 Logistic Plan ....................................................................................................... 79 14.1 Storage Yard .............................................................................................................................. 79 14.2 Master Schedule ....................................................................................................................... 79 14.3 Manpower Plan ......................................................................................................................... 79 14.4 Equipment Plan ......................................................................................................................... 80

15 Health and Safety ............................................................................................... 82 16 Attachment: ........................................................................................................ 82

Appendix A Risk assessment

Appendix B Insert for temporary support layout

Appendix C Insert for temporary support detail

Appendix D Interface TC and processor

Concrete floor calculation see RFI

Site assembly yard plan dwg

Banana truss erect plan see attachment dwg

Page 4 of 82

1 Preface

PTB contains four main structural parts: Piers, Terminal Processor, International Hub, and Boarding

Bridge. The installation method for space frame roof in the terminal processor and international

hub is not stated in this document.

The total PTB covering area is about 220,000m2, with a length 1500m and width 1000m.

Piers contain columns and space truss roof. This statement applies to both of them.

Terminal processor contains support columns, space frame and shed framing, and this statement

only applies to the support columns and shed framing.

International hub contains support columns, gills truss, perimeter beams and space frame roof.

This statement only applies for the support columns, gills truss and perimeter beams.

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2 Scope of Work

According to project specs, drawings and contract, this statement describes the installation method

for the following steel parts:

2.1 Pier

Structure Introduction Pier is also named as concourse and could be described by single pier at zone B, C, E and double

pier at Zone F, G and D. The steel structure covering the 2nd civil floor is composed of cranes

(240PCS), H section roof, catwalk (only for double pier) and casting foot joint.

The supports columns composed of curved arch columns and the webs welding on it. Their

sections are CHS101.6X10~CHS475X14, UB127X76X13~UB838X292X14, CUB686X191X67,

UC254X254X132 and UC305X305X240.

2.2 Terminal Processor

Structure Introduction The terminal processor covers the 3rd civil floor and covering an area of approximately 66000m2. It

contains south facade, tree and tripod, north columns, space frame and shed framing.

JGS will erect all steel structures of terminal processor except space frame. The following

paragraphs give an introduction to each part of terminal processor

Double pier Single pier

Page 6 of 82

South facade

South façade is made up of 64 banana trusses and 826 transoms. Banana truss is connected with

space frame by bolts sphere joints, and welded with transom. There is a third segment between top

and bottom tusk. The length of the bottom segments is 11m, while the top segments range from

14m to 25m. The tusks range from 5.3ton to 19.5ton, and the total weight is about 1661 ton. Each

banana truss is constituted of front chord, rear chord and web member. The section of chord

ranges from CHS 219.1x10 to CHS244.5x25. The section of web ranges from CHS 168.3x12.5 to

CHS 193.7x16. The typical section dimension of transom is CHS 168x10, CHS 193.7x12.50.

Drawings below are for detail connection of tusk:

Top connection Interface with concrete +14.9m Base plate

Shed Framing

Detail at Level 3

South façade head

South facade

North Column

Tree and

tripod

Tree bottom 24pcs Detail at Level 1

Soffit

Page 7 of 82

88 trees and 6 tripods Tree columns with length ranging from 9.8m to 22.3m and weight ranging from 3.6 ton to 8.2 ton

for each tree. There are 6 tripod columns with length ranging from 26 to 30m, weight ranging from

9.6 to 10.9ton for each tripod.

The sections of tree and tripod column are CHS762x20.

North column There are 54 North columns. Their sections are CHS 457x16, and their lengths are 7.5m~14.1m

with their weight ranging from 1.6 ton to 2.5 ton. The whole weight is about 100 tons.

Tree support Tripods column

Page 8 of 82

Shed frame: Shed frame is made up of about 11800 beams, weighting total 1633 tons with length 3.3m to

28.3m, and typical section dimension CHS140x6.3,UB250*250*16, RHS203.2*203.6*7.2*11. The

weight of the heaviest beam is 0.7 ton.

2.3 International Hub

Structure Introduction International hub roof covers the 2nd civil floor and covering an area approximately 50000m2. It

contains arches, sloped columns, gill columns, gill trusses, perimeter beams and space frame.

JGS will do the installation of the steel structure except for the space frame.

North column

Page 9 of 82

There are 18 piece of Arches and 9 pieces of Sloped Columns in International Hub，Arches and

Sloped columns are on the second floor .Their length is 29 m and 16.5 m ; The section is RHS

600x40 (arches) and CHS 559x25 (sloped columns), and the weight is 20ton and 5.4 ton。

There are 54 pieces of Gill Columns distributed on Level 2 and Level 3 except GC20s that are on

Level 0, so their length are 10.6m, 14.9m, 25.9m respectively. Their section is different from CHS

406x16 to CHS508x50, and the weight is from 2.59 t to 6.08 t.

The gills trusses have a curved shape and are the key to make the project successful.

There are 15 pieces of Gills Trusses having 5 pieces of South Gills Trusses and 5 pieces of

Northwest Gills Trusses and 5 pieces of Northeast Gills. The weight of South Gills is from

12.6~70.38 ton and North Gills are from 14.5~63.8 ton. Both of their Height is from 4.5~7.7 m .The

section is as follow:

CHS193.1X10, CHS219.1X12.5~20, CHS273X20, CHS323.9X12.5~25CHS457X25, CHS457X40

2.4 Boarding Bridge

Totally 46 boarding bridges will be installed on site. The members are mainly H section and Box

section. Connections will be bolted on site and requires high erection accuracy.

Arch

Gills Truss

Gills Columns

Perimeter Beam

Sloped Column

GC20

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2.5 Reference Standards:

The reference of standards to be made in accordance with the following:

Project specification Section 051200 “Structural Steel Framing”

IBC2006 International Building Code

AISC "Manual of Steel Construction", 13th Edition.

AISC 303-05 "Code of Standard Practice for Steel Buildings and Bridges"

AICS/ RCSC-04 "Specifications for Structural Joints Using ASTM A 325 A490 Bolts"

AWS D1.1-08 "Structural Welding Code"

3 Personnel Roles and Responsibilities

The overall responsibility of KAIA PTB Steelwork as below:

SBG (Main Contractor) Saudi Binladin Group

RSS (Steel Subcontractor) Roots Steel

JGS (Steel Supplier & Erector) Jinggong Steel

4 General Construction Introduction

4.1 Schedules

The total schedule duration is 16 months, starting from the project commencement to the time of

steel structure erection completion.

Before the site erection, it requires at least 6 months for the following process:

Detailing drawing, procurement, fabrication, trail assembly, delivery.

1st Aug 2012 assumed as commence on site work, totally 10months for site installation

The main contractor is follow the submitted base line Schedule and meet the mentioned date for

the steel structure delivery to site and installation works.

4.2 Site Plan

Site assembly yard see attachment

storage yard shall be 610mx86m, 52460m2;

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4.3Manpowerplan

The maximum manpower on site shall be 292.

4.4MechanicalandEquipment

All tower cranes to be used by steel contractor shall complete the handover a month before

steel installation. During the installation, steel contractor shall have the priority to use the

cranes.

Piers: 8 railed tower cranes

Terminal Processor: 9 fixed tower cranes

International Hub: 6 fixed tower cranes

Mobile crane 400t will be used for erection of piers in the cross zone between Zone B and

Zone D

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4.5GeneralWorkProcedures

The concrete works handover sequence is assumed in this statement. The handover shall

be 1 week prior to steel structure installation commencement. Accurate surveying report for

the concrete works to be provided to the erector prior starting erection, to ensure the entire

structure conformity. The above mentioned report shall be provided to the erector for action

and to CM for information. In case of any site modifications are required due to unconformity

between the concrete works and steel erection works a detailed report is to be submitted for

CM approval.

All tower cranes that are to used by steel contractor shall be taken over a week prior to steel

installation. During the steel installation, steel contractor has the priority to use the cranes.

The shed framing installation commences after the space frame execution is finished in

terminal processor, the temporary supports and scaffolding shall remain for JGS use.

4.5.1 Pier

The members will be transported to site as members in bulks.

Trial assembly will be executed to ensure the accuracy for fabrication.

The erection units named “crane” will be assembled on the ground in the pre-assembly area

and then lifted by the railed tower cranes to 2nd civil floor. Total nos. of “crane” for erection is

240.

The roof members will be installed after the “crane” is in its position.

The welding work will be done on the ground for the “cranes” to be assembled. All other

erection work is by bolt.

Totally 8 railed tower cranes are required, 4 of 8 have the capacity of 17.9t @ 27m and the

other four have the capacity of 12t @ 34m.

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4.5.2 Terminal Processor

All the columns, soffit steel, shed framing steel will be transported to site in bulks with

maximum a length of 17m, the south facade will be divided to 3 units as a truss segment.

A crawler crane will be used to lift the south facade units and then to be assembled as a

complete truss on the ground in the designated pre-assembly area.

Transom will be erected by tower cranes and the welding done with the brackets.

The tree columns, north façade columns will be erected by 9 fixed tower cranes, which have

the capacity 5.7t @ 50m.

The shed framing shall be installed with space frame erection unit prior to lifting

4.5.3 International Hub

All the columns, perimeter beams will be transported to site in bulks with maximum length of

17m. The gill trusses also will be in bulks and assembled on the civil floor to be a complete

erection unit.

Trial assembly will be done to ensure the accuracy for fabrication.

Total 6 fixed tower cranes will be used for lifting the steel having capacity of 8.8t @ 35m.

Any area inaccessible by tower cranes shall be managed by a 35T mobile crane.

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5 AESS requirement

For the architecturally exposed steel structure quality in the project should comply with the AESS

requirements:

≤2.4m first level

2.4~6m second level

≥6m third level

Level one and level two are the visible and the appearance on these levels is critical. A glossy

finish completed with grinding is required.

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6 Site Welding

Field welding shall be carried out as per the approved Welding procedure specification

(WPS)

Due to the significant number of site welding joints, an independent testing and

inspection agency will be engaged to perform site testes and inspection. The attendance

and numbers of the agency inspectors shall be according to the welding inspection

requirements and will not hinder the erection schedule.

Welding plan shall be prepared and updated daily by the assigned independent testing

and inspecting agency.

Welding shall be carried out in good climatic and environment condition. In case of

damp climatic condition, additional protection shall be provided to cover the weld area.

All joints are to be dried before welding in damp climatic condition.

In the case of multi layer welding, slag and spatters on each completed bead shall be

removed prior to weld the following layer.

7 Bolting Tightening

Bolt storage: All fastener set shall be delivered in a sealed box, it shall be stored into a

dry space, the sealed box shall be put away from ground. No such box is allowed to be

open before it to be fixed at site.

Bolt tightening shall be carried out after completion of alignment to the specified area. All

bolts / nuts and washers shall be used as per shop drawings and project specification.

Mobile Access Platform or scaffolding platform shall be used during Erection, Bolting

tightening and inspection.

Bolted connection shall be tested and inspection by the independent testing and

inspecting agency according to RSCC’S “Specification for structural joints Using ASTM

A325 or A490 Bolts”.

8 Touch Up Painting Procedure

Site Painting for site welding area. The welding shall be cleaned by using electrical sand disc or wire brush. Surface

profiles check shall be completed on the ST3 finish using testex tape.

Prior to the application, foreign material adhering to the surface shall be removed by

using hand / Mechanical clean by sand disc and dry cotton cloth to maintain SSPC-SP2

or SSPC-SP3 surface preparation.

Paint (Primer to top coat) shall be applied as per project specification by using hand

brush / roller. (As per below flow chart).

The following painting system shall be used.

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S/No Applicable Area Location Coating layer

Paint Type Painting DFT

1 Structural Steel painting system – As per the specification051200: Structural steel framing – clause 3.3.N. & 3.6 repairs and protection

Primer epoxy 125μm Intermediate Coat

epoxy 155μm

Final Coat polyurethane 80μm

Touch-up painting shall be carried where the paint surface is damaged during transit. Only approved paint shall be used for touch up painting work.

Prior to the application, foreign material adhering to the surface shall be removed by

SSPC-SP 2 hand-tool cleaning or SSPC-SP 3 power-tool cleaning.

Touch up painting (primer and top coat – for deep damage & top coat for small depth

scars & minor paint scars on top coat) shall be carried out by using hand brush / roller.

(see below flow chart for site painting)

Flow chart for Site Painting Touch-up (Repair) & Paint Work (Welds)

Identify the Location of Painting touch (Repair) work & Painting work (weld)

Check the Atmospheric Condition & Type of Painting System

Clean the painting damage area / Weld joint by: 1. Wire brush cleaning 2. Mechanically surface preparation to level ST3 (SSPC SP-3) by sanding disc for weld

joint area & major paint damaged area, the surface profile shall be test accordingly. 3. Hand sanding with 80 grade sand paper feathering back the existing coating to revel a

tight edge. The repair overlap distance on the existing coating shall be minimum 5mm 4. Solvent cleaning with approval Thinner with lint free cloth and allow to fully dry

before proceeding with the original coating system.

After check the cleaning surface – (Ref: Painting System table): 1. 1st Applied Strip coat paint at corner/holes/bolts/welds by brush. 2. All splice plate edges, fasteners edges shall be sealed with paint during strip coating. 3. After Strip coat all touch up area shall be paint by brush / roller uniformly as required paint thickness. 4. Top coat, before top coat paint application the first coat paint should dry minimum 2-3hours 5. Strip coating with top coat to sharp edges shall also be applied for the top coat. 6. Before applied top coat, the surface shall be clean by Cloth / brush 7. Applied top coat paint as required thickness

Check the Painting DFT / Visual Inspection

Page 17 of 82

9 Installation Method for Pier

9.1 Shipping Unit

The structure of pier shall be transported as illustrated considering the transportation, size

condition, connection type, appearance, etc.

For double Pier (Zone D, F & G), the shipping unit is as indicated below:

For Single Pier (Zone B, C, E), the shipping unit as indicated below:

For Roof Beams: Secondary Trusses are shipped in two pieces as shown in the picture while the

other beams are to be delivered in bulk.

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9.2 Erection Units

The erection unit shall consider the crane capacity, critical weight to minimize the installation work

mid-air.

The piers (green) could be erected by tower crane as complete unit. The piers (yellow) shall be

broken by one beam. The (red) one shall be installed by 400t mobile crane as a a complete set.

9.3 Detailed Erection Unit and weight

Conclusion:

Total Amount：240 PCS

Complete Units: 118 PCS, 50%

Part Assembly:102 PCS, 42%,by 25t mobile

crane on the floor and 8033.16

Mobile Crane:20 PCS, 8%, by 400t mobile

crane

Zone B, C 52 PCS(12.01t@29m<[email protected])

Zone E 60 PCS (25t mobile crane)

THE ENGINEER:



THE CONTRACTOR:

Contractor: Saudi Binladin Group Doc. Ref. No.: 421-DCS-MST-S-00002 Rev. 00

Contract No.: J-10-421-PF-0 Date Issued: 02 February 2012


Page 19 of 82

Zone F, G 76PCS (15.9t@29m<[email protected])

Zone D

32PCS (14.78t@31m<15.48t@31m)

Zone H

20 PCS (20.4t@27m<25.3t@27m)

Page 20 of 82

9.4 Crane Analysis and Selection

9.4.1 Crane selection and site position

Railed Tower Crane position: The railed tower crane shall be located at a distance from the concrete as detailed below:

Page 21 of 82

Page 22 of 82

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9.4.2 Crane Capacity Analysis

(Green) Denotes means erected by 16t tower crane.(see crane plan)

(Red) Means erected by 400t mobile crane of zone H, by 25t mobile crane on the floor of zone

B、C、E . Concrete floor calculation see attachment.

No. Zone AXES New Rev Weight

Radius for RTC

Crane Capaciy Burden

%

1

F、G

NE56 15.9 29m

WOLLF 8033.16

16.5 96%

2 NE54～NE26 15.54 29m 16.5 94%

3 NE24 15.7 29m 16.5 95%

4 NE20、22 16 29m 16.5 97%

5 NE18 19.7 29m 16.5 119%

6

D

N26～S33 14.9 29m 16.5 90%

7 S31～S29 15.7 29m 16.5 95%

8 S27 16.1 29m 16.5 98%

9

B、C

SE47 25.37 29m 16.5 154%

10 SE45、43 22.55 29m 16.5 137%

11 SE41～SE3 21.84 29m 16.5 132%

12 S1～S5 21.84 29m 16.5 132%

13

E

N24～N20 17.4 29m 16.5 105%

14 N18 19.7 29m 16.5 119%

15 N16、14 20.3 29m 16.5 123%

16 N12、10 23.9 29m 16.5 145%

17 N8～N2 24.4 29m 16.5 148%

18 NE2～NE10 24.4 29m 16.5 148%

19 NE12～NE18 20.4 29m 16.5 124%

20 NW2、4、6 24.4 29m 16.5 148%

21 NW8、10 24.1 29m 16.5 146%

22 NW12 20.48 29m 16.5 124%

23 NW14、16 20.3 29m 16.5 123%

24 NW18 19.7 29m 16.5 119%

25

H

S25～S21 18.45 35m

mobile crane 400t

30 62%

26 S19 24.1 35m 30 80%

27 S15～S17 25.2 35m 30 84%

28 S13～S7 21.84 35m 30 73%

Remark Contain Tool 0.5t。

Page 24 of 82

9.5 Temporary Supports

9.5.1 Temporary Supports layout

A. Assembly yard plan see attachment《KAIA zone pier assembly yard plan》: B. Setting temporary supporting using by expansion bolt.

Please ref to attachments appendix B embedded parts layout and appendix C embedded detail.

9.5.2 Ground Hardening Measurement

The floor under the assembly support should take the measurements as follow:

20dia expansion bolt to fix the support

Temporary supporting

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9.5.3 wind rope

Insert the embedded for fix wind rope during concrete pouring. All temporary support and completed steel structure should be using wind rope as safety

required.

9.6 Detail erection method 9.6.1 Pier Erection Sequence

The Pier Erection sequence is illustrated in the picture below. Procedure: crane assembly on the ground, crane erection, roof beam, side walk and some

other ancillary facilities Start from F, G, B, C, with the railed tower crane and move towards Zone D and Zone E. Eight railed tower cranes are required in total.

Page 26 of 82

9.6.2 Erection Sequence For Double Pier

Step1: Loft & deploy supports Step 2: Erect the curve column

Step 3: Erect the “crane” Step 4: Erect the roof truss

Step 5: Completing the joint

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Step 6: Erect the other beams Step 7: Final Touches

9.6.3 Erection Sequence For Single Pier

Concrete floor calculation see attachment.

Step 1: Loft & deploy supports Step 2: Erect the curve column

Step 3: Erect the “crane” Step 4: Erect the sword and column

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Step 5: Erect the Curve part connection Step 6: Erect the Low span truss

Step 7: Web member assembly Step 8: Final touches

Step 9: Erection the roof truss Step 10: Erect other beams

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9.6.4 Erection Sequence For International Pier

Step 1: Casting& deploy supports Step 2: Erect the Dome

Step 3: Erect the High span Truss Step 4: Erect the web member

Step 5: Erect the sword Step 6: Erect the Curve part connection

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Step 7: Erect Low span Truss assembly Step 8: Erect the web member

Step 9: Erection the roof truss Step 10: Erect other beams

Workers are on the movable scaffolding platforms to erect the beams

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9.6.4 Assembly on the ground

Double pier assembly Step 1: Assembly the crane truss

Step 1: support setting assembly Step 2: Casting assembly

Step 3: Sword and Dome assembly Step 4: Middle Connection assembly

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Step 5: Curve part connection assembly Step 6: Crane truss assembly

Step 7: Web member assembly Step 6: Final Touches

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Single pier assembly

Step 1: Assembly support setting and truss Step 2: Assembly casting

Step 3: Dome assembly Step 4: High span Truss assembly

Step 6: A-frame and web member Step 6: Half crane finish

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10 Erection Method for Terminal Processor 10.1 Shipping units The structural elements of terminal processor building shall be transported as detailed below, considering transportation size condition, connection type, appearance, etc.

10.1.1 South facade

Length of element is 12m. Detail division method is as follow: lower segment 11.5m, middle segment 12m~16m, upper segment 5~13m. The lower segment and the middle segment is naturally separate. Drawing below is its detail method.

Upper and middle segment division

10.1.2 Tree and tripod

Shipping of Tree and tripod is classified to two kinds. Red one is erected by two pieces and black one is erected by one piece.

(Red) ones are divided into two units, (Black) ones are shipped as one unit

Type one: (>17.8m) T1、T2、T5、T6 and tripod (total 38 pieces) is divided to two segments to transport, T6 (16.8m) is divided for weight as it cannot be lifted up by fixed tower crane.

Upper segment Middle segment

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Type 2: (≤17.8m) T3,T4,T7,T8,T9,T10,T11 (total 56 pieces) shipped as one unit.

10.1.3 North column shipped as one unit

10.1.4 Shed frame shipped in bulk.

10.2 Erection Weight and Selection of Cranes

10.2.1 South Façade and Tripod

The weight of south façade tusk and tripod column is about 23 ton，so we consider to use 500ton crawler crane erect. analysis：loading capacity of 500t crawler crane at boom length 102m and working radius 75m is 47ton > 23 ton+0.4 ton（lifting hook and sling）

500t crawler crane

Banana truss erect plan see attachment dwg

Page 36 of 82

10.2.2 Lifting of tree columns on slabs

Tree columns of T1, T2, T6 as lifted by tower in two pieces after being shipped to site, other tree columns should be pre-assembled before lifting. Drawing below is about the location of tower cranes, each color and circle represents one tower. (Green)：T36, T37 70m Wolf7532.12

(Red)：T41 60m Wolf7532.12

(Blue)：T40, T 42 70m Wolf7532.12

(Pink)：T39, T43 60m Wolf7532.12

Location of tower cranes

Analysis of lift sequence for tree columns (same crane location above drawing)

Page 37 of 82

NO.

lgth(m) wt(T)wt*1.2(T

)cranenumber

liftingweight(t

)

lgth ofmainboom

radius(m)

cranecapactiy

(T)

burdenrate(T)

T1-1 22.3 8.2 9.8 T41 4.9 60 39.0 7.5 65.3%T1-2 21.5 7.9 9.4 T41 4.7 60 42.4 6.6 71.5%T1-3 21.1 7.7 9.3 T41 4.6 60 52.9 5.1 90.8%T1-4 21.9 8.0 9.6 T41 4.8 60 50.4 5.1 94.3%

T2-1 20.0 7.3 8.8 T36 4.4 70 58.3 4.2

104.6%[95.8%(10% saftyratio)]

T2-2 19.3 7.1 8.5 T36 4.2 70 49.3 5.3 80.0%T2-3 18.9 6.9 8.3 T36 4.2 70 53.4 4.7 88.3%T2-4 19.3 7.1 8.5 T36 4.2 70 54.5 4.7 90.2%T3-1 17.8 6.5 7.8 T36 2.9 70 32.3 8.0 35.8%T3-2 17.1 6.3 7.5 T36 2.7 70 27.0 9.6 28.6%T3-3 16.8 6.1 7.4 T36 2.7 70 18.5 11.8 22.9%T3-4 17.5 6.4 7.7 T36 2.8 70 23.0 11.8 23.8%T4-1 15.8 5.8 6.9 T36 2.5 70 27.7 9.6 26.5%T4-2 15.1 5.5 6.6 T36 2.4 70 31.0 8.0 30.3%T4-3 14.9 5.5 6.5 T36 2.4 70 24.5 11.8 20.3%T4-4 15.5 5.7 6.8 T36 2.5 70 20.0 11.8 21.1%T5-1 18.9 6.9 8.3 T42 3.0 70 24.0 11.8 25.7%T5-2 18.2 6.7 8.0 T42 2.9 70 28.7 9.6 30.5%T5-3 17.3 6.3 7.6 T42 2.8 70 30.6 8.0 34.8%T5-4 18.0 6.6 7.9 T42 2.9 70 26.2 9.6 30.1%T6-1 16.8 6.1 7.4 T42 3.7 70 55.5 4.2 87.8%T6-2 16.1 5.9 7.1 T42 3.5 70 61.0 3.8 93.0%T6-3 15.4 5.6 6.8 T42 3.4 70 61.8 3.8 89.0%T6-4 16.0 5.9 7.0 T42 3.5 70 56.4 4.2 83.7%T7-1 15.2 5.6 6.7 T36 2.4 70 39.8 6.9 35.4%T7-2 14.5 5.3 6.4 T36 2.3 70 37.3 6.9 33.8%T7-3 13.8 5.1 6.1 T36 2.2 70 48.2 5.3 41.8%T7-4 14.5 5.3 6.4 T36 2.3 70 39.8 6.9 33.8%T8-1 13.0 4.8 5.7 T36 2.1 70 37.3 6.9 30.3%T8-2 12.4 4.5 5.4 T36 2.0 70 39.8 6.9 28.9%T8-3 12.0 4.4 5.3 T36 1.9 70 47.5 5.3 36.4%T8-4 12.4 4.5 5.4 T36 2.0 70 45.6 5.3 37.6%T9-1 14.2 5.2 6.2 T43 2.3 60 22.6 12.0 19.0%T9-2 13.5 4.9 5.9 T43 2.2 60 25.0 12.0 18.1%T9-3 12.6 4.6 5.5 T43 2.0 60 19.5 12.0 16.9%T9-4 13.2 4.8 5.8 T43 2.1 60 16.3 12.0 17.7%T10-1 12.5 4.6 5.5 T43 6.6 60 52.6 5.1 39.4%T10-2 11.9 4.4 5.2 T43 1.9 60 47.0 5.8 33.0%T10-3 11.1 4.1 4.9 T43 1.8 60 48.2 5.8 30.8%T10-4 11.6 4.2 5.1 T43 1.9 60 53.7 5.1 36.6%T11-1 10.9 4.0 4.8 T35 1.8 60 19.7 12.0 14.6%T11-2 10.4 3.8 4.6 T35 1.7 60 14.6 12.0 13.9%T11-3 9.8 3.6 4.3 T35 1.6 60 17.8 12.0 13.1%T11-4 10.2 3.7 4.5 T35 1.6 60 22.2 12.0 13.7%

LIST OF ERECTION UNIT AND CRANE CAPACITY

characters crane

Page 38 of 82

10.3Temporary support

10.3.1 Temporary support layout

Insert plate during concrete pouring 300*300*16 Temporary support weld to the plate Please ref to attachments appendix B embedded parts layout and appendix C embedded

details

10.3.2 Head & Bottom Connection

Tack welding

Page 39 of 82

10.3.3 Wind rope


required.

10.4 Detailed Erection Method for Terminal Processor

10.4.1Erection Sequence

Erection tree column start from center to both side. Space frame will installed follow the steel structure schedule. The roof frame will install after space frame completed. Remove the temporary support when work is completed, space frame and steel structure using separately.

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10.4.2 Erection process

South facade Step 1: Erect the lower segment of tusk of

south façade Step 2: Erect upper segment of south facade

Step 3: Erect transom between tusk for south facade

Step 4: Weld transom

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Tree

Shed frame Shed frame Installation in location after Space frame are installed.

Temporary catwalk will be installed on space frame to help installation of shed frame. See

picture below.

Soffit purlins installation use boom length 26m man lift . 26m man lift 2pcs.

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Step 1：Erect the first beam and short beam component

Step 2:

Step 3: Step 4：

Step 5: Erect from axis G0 to axis G11 Step 6: Erect from center to side

Step 7: Erect from axis NS to axis TW、TE Step 8: Erect from axis NS to axis TW、TE

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Page 44 of 82

11 Erection Method for International Hub 11.1 Shipping Unit Shipping Units should satisfy the capacity of transportation and easy to assembly. It’s better to being segmented at the different sections:

11.1.1 Arches and Sloped Columns

Arches: Total length is 29m and divided into 2 with 14.5m length（36units, 8.5t for each）

Sloped Columns: (9 units，5.4t per piece)

11.1.2 Gills Columns

Type 1: 10.6m~14.9m, delivered in one piece（50 units, From 2.28 to 6 t）

Type 2: 25.9m, deliver in two pieces（4 Units, 3 t per piece）

11.1.3 Arches Connection

Arches(Sloped Column) Space Connection and Base Connection(9 units,14tper Space Connection, 2.7 t per Base Connection)： Both of them are delivered as single piece

11.1.4Gills Trusses

Gills trusses are delivered as single pieces, the length of web member is 4~7m. We should control the chord member in 9~15m as the following illustration:

14.5m 14.5m

25m

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11.1.5 Perimeter Beam

The perimeter beams are delivered as single units. If the length is shorter than 12.5m we deliver it as one unit, the others are delivered in two pieces. There are 84 straight pieces and 6 arc pieces in total:

11.2 Erection Units The tower crane type and position are unchangeable, the Erection Units should meet the followed principle： A. Under the capacity of tower crane 。

B. Easy to set temporary supporting。

C. Easy to transport and raise up。

D. Control the single pieces, improve the progress

11.2.1 Arches and Sloped columns

The arches shall be erected as two pieces, the sloped one shall be as one piece.

12.5m

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11.2.2 Gills Columns

11.2.3 Connection units as shipping unit

11.2.4 Gills Truss

Gills 1 (8 Erection Units)


H: 14.85m

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Page 48 of 82

11.2.5 Perimeter Beam：

11.3 Erection Weight and Crane Analysis

11.3.1 Tower Crane Layout:

Some units’ weight is above the Tower Crane capacity. In such cases, we will use 35t mobile crane to raise them.

25m

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11.3.2 Tower Crane and Mobile Crane capacity analysis:

TW14

TW18

TW17

TW1

TW16

TW1

○M 35tmobile crane

Page 50 of 82

Crane capacity analysis of Sloped Columns and Arches

List of Erection Units & Crane Capacity

No. PCS Characters Wt*1.2 Crane

Light of

Radius (m)

Crane Capacity(t)

Burden Rate

Main Boom

Light Weight Kg/m (m)

SC1 1 16.5 5.4 327 6.48 TW15 60 40 7.5 86%

AR1a 1 14.4 8.5 590 10.2 MC 14.4 6 17.2 59%

AR1b 1 14.4 8.5 590 10.2 MC 15.6 6 15.6 65%

AR1c 1 14.4 8.5 590 10.2 TW15 60 30 10.4 98%

AR1d 1 14.4 8.5 590 10.2 TW15 60 19.4 12 85%

SC2 1 16.5 5.4 327 6.48 TW15 60 20 12 54%

AR2a 1 14.4 8.5 590 10.2 TW15 60 12 12 85%

AR2b 1 14.4 8.5 590 10.2 TW15 60 12 12 85%

AR2c 1 14.4 8.5 590 10.2 TW15 60 11 12 85%

AR2d 1 14.4 8.5 590 10.2 TW15 60 9 12 85%

SC3 1 16.5 5.4 327 6.48 TW15 60 35 8.8 74%

AR3a 1 14.4 8.5 590 10.2 TW15 60 17 12 85%

AR3b 1 14.4 8.5 590 10.2 TW15 60 25 12 85%

AR3c 1 14.4 8.5 590 10.2 TW15 60 30 10.4 98%

AR3d 1 14.4 8.5 590 10.2 MC 19.5 6 15.6 65%

SC4 1 16.5 5.4 327 6.48 MC 14.4 6 17.2 38%

AR4a 1 14.4 8.5 590 10.2 MC 19.5 6 15.6 65%

AR4b 1 14.4 8.5 590 10.2 MC 14.4 6 17.2 59%

AR4c 1 14.4 8.5 590 10.2 MC 14.4 6 17.2 59%

AR4d 1 14.4 8.5 590 10.2 MC 19.5 6 15.6 65%

SC5 1 16.5 5.4 327 6.48 TW16 60 19 12 54%

AR5a 1 14.4 8.5 590 10.2 TW16 60 25 12 85%

AR5b 1 14.4 8.5 590 10.2 TW16 60 17 12 85%

AR5c 1 14.4 8.5 590 10.2 TW16 60 12 12 85%

AR5d 1 14.4 8.5 590 10.2 TW16 60 12 12 85%

SC6 1 16.5 5.4 327 6.48 TW16 60 22 12 54%

AR6a 1 14.4 8.5 590 10.2 TW16 60 13 12 85%

AR6b 1 14.4 8.5 590 10.2 TW16 60 15 12 85%

AR6c 1 14.4 8.5 590 10.2 TW16 60 21 12 85%

AR6d 1 14.4 8.5 590 10.2 TW16 60 27 11.2 91%

SC7 1 16.5 5.4 327 6.48 MC 14.4 6 17.2 38%

AR7a 1 14.4 5.4 375 6.48 TW16 60 37 8.3 78%

AR7b 1 14.4 5.4 375 6.48 MC 14.4 6 17.2 38%

AR7c 1 14.4 5.4 375 6.48 TW17 60 43 7 93%

AR7d 1 14.4 5.4 375 6.48 TW17 60 35 8.8 74%

SC8 1 16.5 5.4 327 6.48 TW17 60 16 12 54%

AR8a 1 14.4 8.5 590 10.2 TW17 60 25 12 85%

AR8b 1 14.4 8.5 590 10.2 TW17 60 12 12 85%

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AR8c 1 14.4 8.5 590 10.2 TW17 60 10 12 85%

AR8d 1 14.4 8.5 590 10.2 TW17 60 15 12 85%

SC9 1 16.5 5.4 327 6.48 TW17 60 24 12 54%

AR9a 1 14.4 8.5 590 10.2 TW17 60 16 12 85%

AR9b 1 14.4 8.5 590 10.2 TW17 60 17 12 85%

AR9c 1 14.4 8.5 590 10.2 TW17 60 23 12 85%

AR9d 1 14.4 8.5 590 10.2 TW17 60 30 10.4 98% Crane capacity analysis of Gills Column


No. PCS Characters Wt*1.2 Crane

Light of Main

Boom(m)Radius (m)

Crane Capacity(t)

Burden Rate

Out-capacity

Light Weight Kg/m

GC1 2 10.6 3.15 297 3.78 TW18 70 35 8 47% 0

GC2 2 10.6 2.28 215 2.74 TW17 70 15 11.8 23% 0

GC3 2 10.6 3.97 375 4.76 TW17 70 22.5 11.8 40% 0

GC4 2 10.6 4.88 460 5.86 TW18 70 15 11.8 50% 0

GC5 2 10.6 3.97 375 4.76 TW18 70 30 9.6 50% 0

GC6 1 14.9 2.59 174 3.11 TW18 70 10 11.8 26% 0

GC7 2 10.6 5.97 563 7.16 TW18 70 12.5 11.8 61% 0

GC8 1 10.6 5.97 563 7.16 TW18 70 32.7 8.8 81% 0

GC9 2 14.9 2.59 174 3.11 TW18 70 35 8 39% 0

GC10 2 14.9 2.29 154 2.75 TW18 70 57 4.5 61% 0

GC11W 2 9.9 2.63 266 3.16 TW14 70 35 8 39% 0

GC11E 2 9.9 2.63 266 3.16 TW13 60 55 5.1 62% 0

GC12W 2 9.9 2.63 266 3.16 TW15 60 53 5.8 54% 0

GC12E 2 9.9 2.63 266 3.16 MC 22 10 7.9 40% 1

GC13W 2 14.9 4.43 297 5.32 MC 22 6 12.6 42% 1

GC13E 2 14.9 4.43 297 5.32 MC 22 6 12.6 42% 1

GC14W 2 9.9 3.71 375 4.45 TW14 70 20 11.8 38% 0

GC14E 2 9.9 3.71 375 4.45 TW13 60 35 8.8 51% 0

GC15W 2 9.9 3.71 375 4.45 TW14 70 34 9.6 46% 0

GC15E 2 9.9 3.71 375 4.45 TW13 60 58 4.8 93% 0

GC16W 1 9.9 4.56 461 5.47 TW14 70 10 11.8 46% 0

GC16E 1 9.9 4.56 461 5.47 TW13 60 20 12 46% 0

GC17W 2 9.9 5.57 563 6.68 TW14 70 17 11.8 57% 0

GC17E 2 9.9 5.57 563 6.68 TW13 60 32 9.6 70% 0

GC18W 1 9.9 4.56 461 5.47 TW14 70 33 8.8 62% 0

GC18E 1 9.9 4.56 461 5.47 TW13 60 21 12 46% 0

GC19W 2 9.9 5.57 563 6.68 TW14 70 32 8.8 76% 0

GC19E 2 9.9 5.57 563 6.68 TW13 60 27 11.2 60% 0

GC20W 2 25.9 6.08 235 7.3 MC 30.4 6 9 81% 2

GC20E 2 25.9 6.08 235 7.3 MC 30.4 6 9 81% 1

Page 52 of 82

11.3.3 Gills Trusses

Page 53 of 82

Crane capacity analysis of Gills Trusses: List of Erection Units & Crane Capacity

No. PCS Characters

Wt*1.2 CraneLight of Main

Boom(m) Radius

(m) Crane

Capacity(t) Burden Rate Light Weight Kg/m

SG1a 1 11.4 9.65 846 11.58 TW17 60 20 12 97%

SG1b 1 8 8.51 1064 10.21 TW17 60 14 12 85%

SG1c 1 16.4 8.68 529 10.42 TW17 60 17 12 87%

SG1d 1 16.3 8.83 542 10.6 TW17 60 29 10.7 99%

SG1e 1 16.3 6.89 423 8.27 MC 24.7 6 12.6 66%

SG1f 1 16.4 8.68 529 10.42 MC 24.7 6 12.6 83%

SG1g 1 8 8.51 1064 10.21 MC 24.7 6 12.6 81%

SG1h 1 11.4 9.65 846 11.58 MC 24.7 6 12.6 92%

SG2a 1 9.2 7 761 8.4 TW17 60 24 12 70%

SG2b 1 12.5 4.58 366 5.5 TW17 60 31 10.1 54%

SG2c 1 16.9 8.54 505 10.25 TW18 70 22 11.8 87%

SG2d 1 16.9 6.38 378 7.66 TW18 70 35 8 96%

SG2e 1 12.5 4.58 366 5.5 TW18 70 48 5.6 98%

SG2f 1 9.2 7 761 8.4 MC 24.7 8 10.2 82%

SG3a 1 12.5 7.14 571 8.57 TW18 70 32 9.2 93%

SG3b 1 15.2 6.85 451 8.22 TW18 70 2.6 11.8 70%

SG3c 1 15.2 4.76 313 5.71 TW18 70 18 11.8 48%

SG3d 1 12.5 7.14 571 8.57 TW18 70 32 9.2 93%

SG4a 1 9.4 6.83 727 8.2 TW18 70 16 11.8 69%

SG4b 1 13.9 4.9 353 5.88 TW18 70 13 11.8 50%

SG4c 1 9.4 6.83 727 8.2 TW18 70 16 11.8 69%

SG5a 1 7.7 3.7 481 4.44 TW18 70 30 9.6 46%

SG5b 1 8.2 4.86 593 5.83 TW18 70 34 8.3 70%

SG5a 1 7.7 3.7 481 4.44 TW18 70 30 9.6 46%

NWG1a 1 11.4 9.8 860 11.76 MC 24.7 6 12.6 93%

NWG1b 1 8 7 875 8.4 TW15 60 26 11.7 72%

NWG1c 1 16.4 8.78 535 10.54 TW15 60 25 12 88%

NWG1d 1 16.3 8.83 542 10.6 TW15 60 26.7 11.5 92%

NWG1e 1 16.3 6.66 409 7.99 TW15 60 35 8.8 91%

NWG1f 1 16.4 8.78 535 10.54 MC 24.7 6 12.6 84%

NWG1g 1 8 7 875 8.4 MC 24.7 6 12.6 67%

NWG1h 1 11.4 9.8 860 11.76 MC 24.7 6 12.6 93%

NWG2a 1 9.1 6.66 732 7.99 TW14 60 34 9.1 88%

NWG2b 1 15.8 4.29 272 5.15 TW15 60 40 7.5 69%

NWG2c 1 13.7 5.97 436 7.16 TW14 70 36 7.8 92%

NWG2d 1 13.7 4.5 328 5.4 TW14 70 34 8.3 65%

NWG2e 1 15.8 6.66 422 7.992 MC 24.7 8 10.2 78%

NWG2f 1 9.1 4.29 471 5.15 MC 24.7 10 7.9 65%

NWG3a 1 7.14 6.3 882 7.56 TW14 70 35 8 95%

NWG3b 1 7 6.6 943 7.92 TW14 70 17 11.8 67%

NWG3c 1 4.57 5.67 1241 6.8 TW14 70 17 11.8 58%

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NWG3d 1 7.14 6.3 882 7.56 TW14 70 29 10 76%

NWG4a 1 10.3 6.45 626 7.74 MC 24.7 10 7.9 98%

NWG4b 1 16.4 5 305 6 TW14 70 14 11.8 51%

NWG4c 1 10.3 6.45 626 7.74 TW14 70 37 7.6 102%

NWG5a 1 7.7 4.3 558 5.16 TW14 70 30 9.6 54%

NWG5b 1 8.2 4.9 598 5.88 TW14 70 33 8.6 68%

NWG5c 1 7.7 4.3 558 5.16 TW14 70 30 9.6 54%

NEG1a 1 11.4 9.8 860 11.76 TW16 60 20 12 98%

NEG1b 1 8 7 875 8.4 TW16 60 15 12 70%

NEG1c 1 16.4 8.78 535 10.54 TW16 60 20 12 88%

NEG1d 1 16.3 8.83 542 10.6 TW16 60 27 11.5 92%

NEG1e 1 16.3 6.66 409 7.99 MC 24.7 6 12.6 63%

NEG1f 1 16.4 8.78 535 10.54 MC 24.7 6 12.6 84%

NEG1g 1 8 7 875 8.4 MC 24.7 6 12.6 67%

NEG1h 1 11.4 9.8 860 11.76 MC 24.7 6 12.6 93%

NEG2a 1 9.1 6.66 732 7.99 TW16 60 25 12 67%

NEG2b 1 15.8 4.29 272 5.15 TW16 60 33 9.6 54%

NEG2c 1 13.7 5.97 436 7.16 TW16 60 35 8.8 81%

NEG2d 1 13.7 4.5 328 5.4 MC 24.7 10 7.9 68%

NEG2e 1 15.8 6.66 422 7.99 MC 24.7 8 10.2 78%

NEG2f 1 9.1 4.29 471 5.15 MC 24.7 10 7.9 65%

NEG3a 1 7.14 6.3 882 7.56 MC 24.7 10 7.9 96%

NEG3b 1 7 6.3 900 7.56 TW13 60 35 8.8 86%

NEG3c 1 4.57 5.67 1241 6.8 TW13 60 42 7.1 96%

NEG3d 1 7.14 6.3 882 7.56 MC 24.7 10 7.9 96%

NEG4a 1 10.3 6.45 626 7.74 TW13 60 19 12 65%

NEG4b 1 16.4 5 305 6 TW13 60 22 12 50%

NEG4c 1 10.3 6.45 626 7.74 TW13 60 35 8.8 88%

NEG5a 1 7.7 4.3 558 5.16 TW13 60 15 12 43%

NEG5b 1 8.2 4.9 598 5.88 TW13 60 23 12 49%

NEG5c 1 7.7 4.3 558 5.16 TW13 60 27 11.5 45%

11.3.4 Perimeter

Page 55 of 82

Crane capacity analysis of Perimeter：


No. PCSCharacters

Wt*1.2 CraneLight of MainBoom(m)

Radius (m)

Crane Capacity(t)

Burden Rate

Out-CapacityLight Weight Kg/m

S1 2 8 8.7 1088 10.44 MC 19.5 4 18.4 57% 2

S2 2 8 8.7 1088 10.44 MC 19.5 4 18.4 57% 2

S3 2 16.5 11.4 691 13.68 MC 19.5 4 18.4 74% 2

S4 2 13 3.9 300 4.68 TW18 70 47 5.6 84% 0

S5 2 10 5.36 536 6.43 TW18 70 37 7.5 86% 0

S6 2 25.3 9.1 360 10.92 TW18 70 25 11.8 93% 0

S7 2 33 5.9 179 7.08 TW18 70 25 11.8 60% 0

S8 2 36 2.24 62 2.69 TW18 70 45 6 45% 0

S9 1 40 2.47 62 2.96 TW18 70 50 5.3 56% 0

NM1 2 8 8.7 1088 10.44 MC 19.5 4 18.4 57% 2

NM2 2 8 8.7 1088 10.44 MC 19.5 4 18.4 57% 2

NM3 2 16.5 11.4 691 13.68 MC 19.5 4 18.4 74% 2

NM4 2 13 3.9 300 4.68 TW14 70 47 5.7 82% 0

NM5 2 10 5.36 536 6.43 TW14 70 40 6.9 93% 0

NM6 2 25.3 9.1 360 10.92 TW14 70 25 11.8 93% 0

NM7 2 33 5.9 179 7.08 TW14 70 27 10.7 66% 0

NM8 2 36 2.24 62 2.69 TW14 70 41 6.7 40% 0

NM9 1 40 2.47 62 2.96 TW14 70 45 6 49% 0

Page 56 of 82

NE1 2 8 8.7 1088 10.44 MC 19.5 4 18.4 57% 2

NE2 2 8 8.7 1088 10.44 MC 19.5 4 18.4 57% 2

NE3 2 16.5 11.4 691 13.68 MC 19.5 4 18.4 74% 2

NE4 2 13 3.9 300 4.68 TW16/MC

60 35 8.8 53% 1

NE5 2 10 5.36 536 6.43 TW16/MC

60 45 6.6 97% 1

NE6 2 25.3 9.1 360 10.92 MC 19.5 4 18.4 59% 2

NE7 2 33 5.9 179 7.08 TW13 60 30 10.4 68% 0

NE8 2 36 2.24 62 2.69 TW13 60 25 12 22% 0

NE9 1 40 2.47 62 2.96 TW13 60 38 7.2 41% 0

(Red) stands for 35t mobile crane in the illustration. It means that the unit are lifted by mobile crane. The other colors stand for different tower cranes in the illustration and forms. As shown in the form, there are 264 units (including 57 single pieces in Gills Trusses). Mobile crane erects 68 of them. A tower crane erects 74.2% of the unit which makes full use of tower crane. 11.4 Temporary supporting

11.4.1 The temporary supporting layout

Arches and Sloped Columns are inclined and they need temporary supports to resist the horizontal forces. Arches are divided into two pieces as shipping unit and Gills Trusses are divided into many units as the erection units shown before. The break position needs temporary support to resist self weight and horizontal force. Based on the erection units.

11.4.2 Temporary Supporting

Insert plate during concrete pouring Temporary support welding to the plate Please ref to attachments appendix B embedded parts layout and appendix C embedded

details

Page 57 of 82

11.4.3 Head & Bottom Connection

11.4.4 Wind rope


required.

11.5 Detailed Erection Method for International Hub

11.5.1 General

International Hub is erected from inside to outside. While erecting the inner part, the outside place can be used for assembly. The Gills Trusses is erected from middle to side outwards. The single part is erected after both side units have been erected and fixed. The man lift is used to reach and weld the single piece into position.

The space frame install will follow the steel structure erection schedule. Using temporary support is separately and removed when work is completed. The erection sequence show as following:

Page 58 of 82

11.5.2 Erection of Lens

Step 1: Position Fix and Base Connection erection

Step 2: Temporary support fixing

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Step 3: Lens arches erection

Step 4: Space Connection erection

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11.5.3 Erection of Gills column

Gill Columns are upright which can be fixed on the floor without temporary supporting directly.But every steel column needs four cables to improve the stability.

11.5.4 Gills trusses erection

Step 1: Loft & deploy supports Step 2: Erect the middle unit

Step 3: Erect the other middle unit Step 4: Adding the single units

Page 61 of 82

Step 5: Erect from middle to side Step 6: The second Gills Trusses erection

Step 7: Erect piermeter beam Step 8: Permeter beam butt joint

Step 9: From inside to outside Step10: Final touches

Page 62 of 82

11.5.5 Gills trusses assembly

Step 1: Chord fixing

Step 2: Adding the web member

12 Erection Method for Boarding Bridge

12.1 General Dimension Boarding Bridge: 46 PCS Weight: 46 ton for each Size: H*B*L=3275mmx5000mmx37000mm Height: 6m~10m Section: UB for chords, Box for webs

Page 63 of 82

12.2 Transportation Units

The transportation method of boarding bridge shall be as side truss, other members in bulk.

Width: 5000

Height: 3275

level：10m

level：6m

Page 64 of 82

12.3 Erection Units The erection weight of bridge shall be less than 23ton.

12.4 Crane Selection Apply: 150 t mobile crane, 25.2m (boom)@11m, 35 ton >23 ton + 0.4 ton (hook)

Page 65 of 82

150t mobile crane

12.5 Erection Method Step 1: Assemble on ground

Step 2: Erect the first unit

Step 3: Erect the second unit

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Step 5: Adding the single piece on the manlift

13 survey schemes

The structure of this project is complicated, with large construction and so much bolt connection joints. And high accuracy requirement make survey work of KAIA PTB Steel structure work very difficult. Installation accuracy control is an important and difficult work on site. So we need to solve many problems in survey work.

13.1 Analysis of difficulties (1) Survey process is more; high elevation locating is difficult.

According to the construction scheme we should first assemble most of components on the ground, then hoist them integrally. In construction process the survey work and process would be increased, so that the accuracy control became very difficult.

(2) The weather is bad; the view condition is very poor. In Jeddah, the weather is very hot and the sunshine is too strong. BetweenAM9:00 toPM4:00 the air temperature is above 40℃,the air current is very uneven and the target is too fuzzy. We can′t view the aim directly by the Total station, because the construction area is too large with a cover of about 1312m×941m, None of the tall building to be used as the survey location, this cause the aims and control points can't be view directly one another. Lots of extra work has to be done to grantee the survey accuracy.

(3) To control the accurate of curve members is difficult. In structure system the sword in Piers and the gill truss in Hub are belongs to the curved tubes. Controlling the curve is a technical difficulty. As the gill truss had lots of joints connect with it, the components can′t be installed successfully if the installation dimensions

Page 67 of 82

exist any mistake. (4) To control the welding deformation is difficult.

There are great deals of welding works in this project; control of the welding deformation is an arduous work. The deviation of deformation dimension will impaired the dimension accuracy directly. So we should control the deviation of deformation dimension both in assembly and installation process. How to solve these difficulties, and ensure the project quality are two vital points the survey work must take into consideration.

13.2 Survey idea and control method We adopt the survey principle that “first whole then part, use high accuracy control point and instrument to make sure small allowance” to measure these survey work difficulties in this project. First we should measure and lay the “First class survey control network”according to the control points provided by special surveying Institute, then measure the local placement, that is to say first the whole engineering were controlled by the high accurate measurement and advanced technology, then every parts and local were controlled . In whole measurement work, we should keep to the principle that is "to control installation accuracy from entirety to part, fabrication precision is small than installation accuracy” and eliminate the error in the every survey process, ensure the installation precision to meet the standard. In measurement process the coordinate system should be set up and adjust according to the design and position principle. All measurement data is based on the design drawing and sections. Site positioning drawing as below:

In observation time, we adopt the method of direction observation in round to measure; we usually using 2 direction observations to measure them. To the place of high precision, we adopt the method of more direction observations to raise the accuracy, the same Total station, survey station and the measurement data are used as the calculate basis, and then the adjustment program is used for ensuring the precision. We main adopt the method of measuring the truss open-location and terminal point to control the whole dimension during the course of assembly and installation. To strictly control the error of every measurement, to prevent the error is accumulating reached the maximum value.

13.3 Accuracy control of anchor bolts To position the anchor bolts, the axis and elevation should be setting-out on reinforcing steel or template by the Total station, and then adopt the method of supporting-wire and bracing wire to position them. The leveling would be used for measure the elevation of anchor bolts; first the leveling points must be measured and marked on the template or reinforcing steel from the nearest elevation control point as the leveling basis. The Total station was used for checking the top of anchor bolts location when the anchor bolts were installed. Finally, all measurement data should be controlled within allowable deviation.

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The tolerances see AISC 303-5 section7.The location of measurement points as below:

13.4 Accuracy control of Zone A Banana trusses

Banana trusses are cut into pieces in shop, and assemble on site at the assembly yard, and then lift up integrally. In construction process, we should consider how to control the assembly accuracy on the ground firstly. We adopt the method of mould bed to control the assembly accuracy that is according 1:1 scale to stake out the axis and control line on assembly yard, and make the control lines, joints and position line. The leveling is used for measuring the elevation of adjustable plate.

To control the accuracy of assembly dimension, we mainly adopt the method of supporting

wire to do it, just ensure the whole dimension and every joints relative position, the diagram as below:

Setting-out the axis and elevation

Position

Measurement point

After concrete placement, location of every bolt should be check by the Total station

The leveling was used for measure the elevation of corresponding location

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Lastly, the Total station is used for checking the whole dimension and relative position

of every joint. The accurate must be controlled within allowable deviation. The detail tolerances see AISC 303-5 section7.

13.5 Installation position for banana truss To position the banana truss, we usually adopt the method of measure the 3D coordinate to control them that are tube center or forth point of open-location.

Just to ensure the measurement points in consistent with work points in design drawing. The

measure diagram as below:

In installation process, the measure data must be satisfied with allowable deviation,

every point should be controlled within tolerance value. We need stake-out the line and elevation on the temporary support before lifting, then wending the limiting plate. The components need to connect the ropes when lifting, and alignment the axis on the temporary supports. After that, we use the wind ropes and hydraulic jack to correct the axis and elevation reached to the allowable deviation. At last, we use the Total station to check the coordinated of control points, if all dates are OK, fix the rope and limiting plate. The detail tolerances see the AISC303-5 section7.

13.6 Positioning accuracy of PIER Pier can be divided into 3 types: double pier, Single pier and International pier. Most of components adopt the bolts connection; to install Pier we should assemble truss, and then hoisting them integrally. So the assembly accuracy must be controlled. During the course of installation, the steel standard and code should be execute and check whole dimension before welding the truss. The truss must be corrected when we found the

We main adopt the method of supporting wire to control it

Measure point)

Measure point (the fourth point of pipe open-l ti )

Measuring points not less than 2)

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dimension accuracy overstep the allowable deviation. The principle and base of survey position

To control the Crane accuracy is the key of Pier ′accuracy control, the accuracy of assembly and installation control were base on 3D model and situation plan. The critical is to control the key joint and location. The model position drawing as below:

During the course of installation, the open location and terminal location should be controlled.

The Total station is used for measure the 3D coordinates of truss open-location; all measurement value is base on design value.

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（1）Temporary supports To design the temporary supports first the assembly yard should be considered, whether the temporary support can satisfy the geometry linear and concrete height of truss. (Assembly yard must be hardening before installing temporary support) the diagram as below:

The allowable deviation table of temporary support (mm)

Item Allowable deviation Check method axis ≤3 Using the steel ruler

elevation (0, +10) Using the Total station

（2）Positioning the casting

The axis and control lines should be staked-out on the assembly yard by the Total station, and the casting base plate should be positioned before assembling the Crane. To position the casting we usually measuring the pipe orifice centre or fourth points by the Total station. The rope and hydraulic jack were used for moving the casting to control the Tolerance.The diagram as below:

Page 72 of 82

During the course of assembly, we need considered the wending shrinkage and settlement. So

we usually let the position value more than or less than design value 5mm.Lastly, the dimension accuracy can reached the allowable deviation.The requirement and accuracy see the AISC303-5 section7.

（3）Positioning accuracy of the curved pipe

To position curved pipe, we adopt the method of combined of supporting wire and plane right angle coordinates to accurate position, first one point should be moved as the survey station from the nearest place, and then the Total station is set up on this point and we adopt the method of measuring the curved pipe center or fourth point 3d coordinate to accurate position. All survey points must be controlled less than tolerance. The detail allowable deviations see the AISC303-5 section7.The diagram as below:

(4) Assembling main truss of double pier on the ground Main truss is first assembled on the ground, and then lift up integrally. To control the

dimension accuracy we should set up a new coordinate system according the truss dimension and linear, and then staking-out the axis, elevation and contour lines. During the

Survey point (the pipe center or fourth point) Survey point

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course of assembly, the dimension accuracy should be controlled by the method of supporting wire and measuring steel ruler. The whole dimension and every key joint position must be checked when truss assembly finished by the Total station.

The allowable deviation see the AISC 303-5 section7 7.13.

(5) Assembly accuracy control of double pier To position the main truss, we adopt the method of measuring the Flange plate center point of

H section steel 3D coordinates to accurate position by the Total station. First the main truss were controlled within the 20mm, and then fixed the rope and wending the limited plate on the support. After control the accuracy within the allowable deviation. We can use the ropes to correct the error. The survey control points diagram as below:

During the course of survey, the coordinates should be translated in the light of actual conditions.

(6) To control the whole dimension of double pier

The whole dimension and key location of double pier must be checked; all error was strictly observed according the standard and code of steel structure. The measuring diagram as below:

Measurement point

Measurement point

Measurement point

Measurement point

Measurement point

Measure point (The center point of H section)

Measure point (The center

i t)

Page 74 of 82

All control accuracy seeing the Code of Standard Practice for Steel Building and Bridge (AISC303-5)

Assembly surveying for Single pier

(1) Temporary supports

Survey method of temporary supports layout and installation the same to double pier. The diagram as below:

（2）Single pier assembly surveying process and method

Step1: To position the casting

Measurement point (The flange plate center point of H section)

Survey point

To measure the key location

Measurement point (center point)

Measurement point (roof hanger)

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Step2: Assembly positioning for curved pipes

Step3: Assembly positioning for section 1

Step4: To position the joint

measurement point1（pipe center or fourth point）

measurement point2（pipe center or fourth point）

measurement point（pipe center or fourth point）

Survey point A (Flange plate center of Cantilever beam

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Step5: Assembly positioning for section 2

Step6: To install the joints

Step8: To check the whole dimension

（Flange plate center of cantilever

To couple

Control

Page 77 of 82

The whole dimension must be checked and measured when all components have finished, the detail requirement and allowable deviation see AISC303-5 section7 Erection. The unqualified location must be corrected again. We can weld them when the error of every survey location should be controlled within allowable deviation.

Installation surveying for Pier.

To loft the location of web member before installing

The key location must be checked

Measure point (open Location)

measure point （cantilever beam of

truss ）

Survey point （cantilever

beam of truss ）

Page 78 of 82

13.7 Assembly and installation surveying for boarding bridge Totally 46 boarding bridge will be installed on site. The members are mainly H section and Box section. Connection will be bolted on site and requires high erection accuracy.

For boarding bridge, we adopt the method of assemble them in sections to install them lying on the ground. To control the assembly accuracy we adopt projection method to do it, in other words, the axis and contour lines of boarding bridge should be lofted on the ground, according to the design drawing and model, and then adopt the method of supporting wire to accurate position. To install the boarding bridge, the axis and elevation of boarding bridge should be lofted on the temporary support before hoisting; lastly, the every dimension and key joints coordinate must be checked by Total station.

■Quality accuracy assurance measure for truss (1) To strict execute the request of assembly technology, and ensured the accuracy of

assembly dimension Many components would be pre-assembling in the factory; the problem should be found and solved before leaving the factory that is maybe happening in site. That ensured the dimension accuracy, section, beveled edges, and making the clearly mark on components. The assembly quality and progress can be raised by this method. So the key measures of ensured quality accuracy are adopting the method of Pre-assembly in factory.

(2) To ensure the assembly accuracy of support on site, and ensured the assembly quality Temporary supports quality will impaired the component of assembly quality, to design the temporary support we must strict according the technology to do it. The temporary support must have the enough strength, and can′t be rock clearly. The temporary support must have the web member connection. We should check the position dimension and elevation, to ensure the temporary support accuracy.

(3)Reinforce the quality management During the course of assembly, the quality scout and check should be executed strictly; the

disqualification components can′t be passed the next process to construct. Insist on prevention first, wall up the quality accident be happened. Define the inspection item,

Installing for second

Installation finished

The assembly di

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inspection standard and method, to demure keep record, date condition and operation staff etc. The disqualification components should be mark and correct timely.

Construction monitoring ■ Deformation survey

To monitor the deformation, we adopt the polar coordinates method to do them in this engineering, to measure the settlement observation we according the observation request and point to do it. The observation point must be installing securely and be using long time. When the steel roof have finished, we must set the observation point, the observation cycle is two months, and the detail plan according the actual conditions to do it. We must call the project department if found have the big displace.

■ Uninstall survey The reflector plates must be stick on the cantilever beam and bottom chord location when the

steel roof structure have finished. During the process of uninstall, all points should be measured by total station. The construction department must be stopped when we found the measure data have a big displace of truss and till make a solving scheme. All support points have uninstalled, we should continue to observation the key points 2 weeks till the data became stability, and then collecting the survey data.

14 Logistic Plan

14.1 Storage Yard

The storage yard must be as close as possible to the site, and it should be as small as possible in accordance with the peak necessity. The peak is expected in July and August as marked in the following table:

The area of the storage yard is 610*86*2=52460㎡ which contains 2 assembly area and 1 check point before unloading, so the remaining area is about 280*86*2=48160㎡. Deducting the road area ,the pure area is about 31360㎡(>23234 ㎡)

14.2 Master Schedule

The total schedule is planned for 16 months, starting from the project commencing date to the completion of steel structure. Before the site erection, it requires 6 months minimum for the following processes: Detailing drawing, procurement, fabrication, trail assembly, delivery. 1st Aug 2012 is assumed as start date and a total of 10months for site installation. 14.3 Manpower Plan

The maximum manpower required is 292 and the welders shall be 60.

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14.4 Equipment Plan

Page 81 of 82

14.5WaterandElectricity

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15 Health and Safety

Site HSE manager will be response to the site safety issues and as a key manager to this

project.

The workers will be made aware of the safety requirements related to this activity through

daily toolbox meeting and safety talk.

Every effort shall be made to assure that employees can accomplish their assigned scope

of work safely.

Carry out provision of the warning sign and isolation requirements on site

Splice joints will be supported by temporary supports and the work platform will also be set.

The movable scaffolding will be the majority facilities for moving.

For the workers, overall equipment will be supplied such as hammer, work suit, safety

harness, safety glass, etc. to guarantee the safety of workers.

Scaffold inspector and erector certifications submit prior start the job.

Fully comply with approved SBG’s safety plan.

16 Attachment:

jalam

November

Ref#421-422-DCS-PLN-G-00027-04

jalam

November

Risk assessment

Appendix A

RISK ASSESSMENT

Risk Assessment Sheet

Form Issue 01 Date: 7 Nov 2012 Author REN

FACILITY

421-F100 RISK ASSESSMENT NO: Steel structure Installation-001

Pages: 16

ACTIVITY

Top coating at site ASSESSMENT TEAM: JGS GEOFFREY RSS JAYAKUMAR

ASSESSMENT DATE: 7 Nov 2012 REVIEW DATE: 7 Nov 2012 ASSESSMENT APPROVAL:

Task Hazard Hazard effect(consequence) C L Risk Proposed Control Measures C LReduced

Risk ALARP

Inadequate knowledge of

Project Requirement

s

Personal injury Injury to others

Ignorant to site regulations

5 4 20

Attend NDIA Safety Induction for New Employees Attend SGW Safety Induction for New Employees A qualified person should be assigned the responsibilities to ensure all personnel comply with ES&H Requirements include hygiene and health sanitation in safety induction All areas shall be kept free of nuisance & safety hazards

3 1 3 YES




Risk ALARP

Moving traffic in and out of the lay down area North

West

Hit by moving vehicle Hit by moving truck

Heat stroke

Wear proper high visibility vest Use adequate PPE Provide shed / covering Provide cool drinking water Provide adequate lighting at work area Provide signalman Provide moving equipment with flasher lights and audible back up alarm




Risk ALARP

Personnel on ground

Hit by moving vehicle Hit by moving truck

Heat stroke

5 4 20

3 1 3 YES Wear proper high visibility vest Use adequate PPE Provide shed / covering Provide cool drinking water




Risk ALARP

CRANE TO BE LOCATED ON LEVELLED

SURFACE & OUTRIGGERS TO BE FULLY

EXTENDED & PLACED ON PACKING.

PRE LIFT PLAN TO BE FILLED OUT PRIOR OF

EVERY LIFT

LIFTING AREA TO BE BARRICADED AS TO

AND SIGNED (KEEP OUT)

TRAINED, COMPETENT RIGGER SHALL BE

APPOINTED AND MUST BE AWARE OF THE

LIFTING PROCEDURE

TAGLINES WILL BE USED

LOADS SHALL NOT BE LIFTED/SLEWED OVER

PEOPLE - AREA WILL BE ISOLATED.


PROHIBIT UNAUTHORIZED PERSONNEL .

OPERATOR SHALL FOLLOW RIGGER

DIRECTIONS - ORDERS

HOT WORKS ELECTRICITY ELECTROCUTION, FIRE 4 4 16 HOT WORK PERMIT SHOULD BE OBTAINED

PRIOR TO WORK. 3 1 3 YES




Risk ALARP

WELDING UNIT SHOULD BE WELL

MAINTAINED & SHOULD BE CHECKED BY

COMPETENT PERSON BEFORE USING.

COMPETENT & EXPERIENCED OPERATORS

SHOULD HANDLE IT.

THE AREA SHALL BE CLEARED OF ANY

COMBUSTIBLE AND FLAMMABLE MATERIALS

PRIOR TO HOT WORKS COMMENCING. -

GOOD HOUSEKEEPING

A FIRE EXTINGUISHER OF A SUITABLE TYPE

SHALL BE LOCATED NEARBY.

A FIRE WATCH SHALL BE IN ATTENDANCE AT

THE LOCATION DURING HOT WORK ACTIVITY

AND ALSO 1 HR AFTER THE WORK.

ALL WASTE ELECTRODES SHALL BE

COLLECTED FROM THE FLOOR IN AREAS

WERE WELDING IS TAKING PLACE AND SHALL

BE STORED IN A SUITABLE METAL

CONTAINER.

DCP FIRE EXTINGUISHERS & FIRE BLANKETS

SHOULD BE AVAILABLE ON SITE




Risk ALARP

APPROPRIATE PPE SHOULD BE WORN

WHICH INCLUDE WELDING HOOD, WELDERS

GLOVES ,COTTON COVERALLS ETC

HAND TOOLS/

POWER TOOL

OPERATION

HAND TOOLS AND

POWER TOOLS

INJURY TO PERSONNEL, ,

DAMAGE TO MATERIAL. 3 3 9

BEFORE HANDING OUT TOOLS, VISUAL

INSPECTION WILL BE CARRIED OUT, BY

COMPETENT PERSON.

2 1 2 YES

HEARING PROTECTION SHALL BE USED IF

EXPOSED TO NOISE LEVELS OF 85 DB(A) OR

ABOVE

COMPETENT OPERATORS SHALL HANDLE

THE TOOLS & COMPETENT SUPERVISION

WILL BE ENSURED.

ALL TOOLS USED WILL BE WELL MAINTAINED

AND DEFECT FREE.

ELECTRICALLY OPERATED TOOLS SHALL

COMPLY WITH OBI / ADCC

REQUIREMENTS-DOUBLE INSULATED /

COLOUR CODED / PROPERLY GROUNDED

APPROPRIATE PPE

GENERAL SITE

CONDITIONS

SLIPS TRIPS FALLS 3 3 9

GOOD HOUSEKEEPING, STARRT TALK FOR

TEAM. 2 1 2 YES




Risk ALARP

USE OF APPROPRIATE PPE ALL TIMES.

WORK ACCESS AREA SHALL BE MAINTAINED

IN A SAFE CONDITION, FREE OF DEBRIS &

MATERIAL THAT WILL POSE A HAZARD.

MATERIALS SHALL BE STORED PROPERLY

ADEQUATE LIGHTING SHALL BE MAINTAINED

AT WORK / ACCESS AREAS WHILE WORKING

AT NIGHT

GRINDING GRINDER

FLYING PARTICLES , EYE

INJURY, OTHER INJURIES

2 3 6

BARRICADE THE AREA & PLACE WARNING

SIGNS

3 1 3 YES

GRINDING WHEEL MUST BE DRESSED

REGULARLY

GRINDER SHOULD HAVE ITS GUARD

SECURED IN PLACE.

FLAME PROOF SCREENS SHOULD BE USED

TO PREVENT SPARKS FALLING ON

PERSONNEL & OBJECTS.

PROPER PPE FACE SHIELD/GOGGLES

SHOULD BE WORN

WELDING ELECTRICITY = ELECTROCUTION, FIRE 5 4 20 BEFORE WORK STARTS THE MACHINE WILL

BE CHECKED BY COMPETENT PERSON . 3 1 3 YES




Risk ALARP

THESE MACHINES SHOULD BE HANDLED BY

EXPERIENCED OPERATORS ONLY

COMPETENT SUPERVISION WILL BE

ENSURED.

THE MACHINES SHALL BE WELL

MAINTAINED AND COLOUR CODED. ENSURE

PROPER GROUNDING

THE MACHINES SHALL BE DOUBLE

INSULATED AND THEIR CABLES AND PLUGS

SHALL NOT BE MODIFIED OR CHANGED.

WELDING FUMES INHALATION OF FUMES 3 4 12

THE WELDING AREA SHALL BE WELL

VENTILATED.

2 1 2 YES

STRICT ADHERENCE TO WELDING PPE

TOOL BOX TALKS WOULD BE CARRIED OUT

AND RISK ASSESSMENT TO BE DISCUSSED

APPROPRIATE PPES TO BE USED

MINIMUM PERSON TO BE IMPLEMENTED ON

WORK




Risk ALARP

WORK ON

SCAFFOLDS

STRUCTURAL

COLLAPSE

SCAFFOLDING

(COLLAPSE OF SCAFFOLD,

FALL OF MATERIAL FROM

HEIGHT ETC. FALL OF MEN

FROM HEIGHT, ACCIDENTAL

MOVEMENT OF MOBILE

TOWER, TUMBLING OF

SCAFFOLD DURING

MOVEMENT)

5 4 20

VEHICLES NOT TO BE ALLOWED TO DRIVE

NEXT TO THE SCAFFOLD. AREA TO BE

BARRICADED.

3 1 3 YES

ERECTION & DISMANTLLING SCAFFOLD TO

BE DONE BY A CERTIFIED AND COMPETENT

SCAFFOLDER ONLY.

PROPER ACCESS TO WORKING PLATFORM

AND WORKING AREA

POLES, LEGS, OR UPRIGHTS OF SCAFFOLDS

SHALL BE PLUMB & SECURELY & RIGIDLY

BRACED TO PREVENT SWAYING AND

DISPLACEMENT

BASE TO RATIO TO BE ADHIRED TO




Risk ALARP

ACCESS/EGRESS LADDER TO BE PROVIDED

ACCESS AND EGRESS THROUGH SCAFFOLD

SHOULD BE THROUGH THE INNER SIDE OF

MOPBILE SCAFFOLD

AREA UNDERNEATH SHALL BE BARRICADED,

WHILE SIGNS INDICATING THAT "MEN

WORKING OVERHEAD" SHALL BE PLACED

LATERAL SUPPORTS REQUIRED TO SECURE

LATERAL MOVEMENT OF THE SCAFFOLDING

SCAFFOLDS SHOULD BE CHECKED

REGULARLY BY COMPETENT SCAFFOLDER

AND SCAFFTAG SYSTEM FOLLOWED.

FALL ARRESTERS SHOULD BE USED AND

SHOULD BE FIRMLY ANCHORED.

MOBILE TOWERS SHALL NOT BE MOVED

WITH PEOPLE ON IT.

CASTOR WHEELS WOULD BE LOCKED TO

AVOID ACCIDENTAL MOVEMENT ON MOBILE

SCAFFOLD.




Risk ALARP

GROUND TO BE FREE OF OBSTRUCTION FOR

LATERAL MOVEMENT OF MOBILE SCAFFOLD.

HANDRAILS, MIDRAILS & TOE BOARD TO BE

INSTALLED AND IF DISMANTELLED FOR

ACCESS OR EGRESS TO BE REPLACED

IMMIDIATELY

MANUAL

LIFTING

MANUAL LIFTING /

MATERIAL HANDLING MINOR INJURY 2 3 6

SAFE METHODS OF MANUAL LIFTING

SHOULD BE BRIEFED BEFORE THE WORK

STARTS THROUGH STARRT TALK.

1 1 1 YES

MANDATORY PPE SHOULD BE WORN ALONG

WITH THICK GLOVES TO PROTECT FROM THE

EDGES OF CORRUGATED SHEET AND NAILS .

CHEMICAL

HANDLING /

STORAGE

PAINT PRIMER

HANDLING / STORAGE POISONING, IRRITATION , FIRE 3 4

12

MSDS TO BE AVAILABLE ONSITE. SAFE

HANDLING PRACTICES SHOULD BE BRIEFED

TO HANDLERS

1 1 1 YES GOGGLES ,MASK & GLOVES WILL BE USED

ALONG WITH OTHER PPE

EYE / HAND WASH FACILITY & FIRST-AID

FACILITY WILL BE PROVIDED ONSITE.




Risk ALARP

POISONING, IRRITATION , FIRE 2 3 6

PRIMER SHOULD BE STORED IN

MANUFACTURER SUPPLIED CONTAINER

ONLY IN WELL VENTILATED AREA AWAY

FROM ANY SOURCE OF IGNITION 1 2 2 YES

DRY CHEMICAL / CO 2 / ALCOHOL RESISTANT

FOAM EXTINGUISHERS SHOULD BE

AVAILABLE ONSITE.

ENVIRONMENT

WASTE CONTAINERS

OF

PAINTS / THINNER

ENVIRONMENT 3 3 9

WASTE CONTAINERS SHALL BE COLLECTED

SEPARATELY AND PROPERLY DISPOSED OFF

BY LICENSED AGENT.

1 1 1 YES

OIL SPILLS

FLUID SPILLS

FROM VEHICLES &

EQUIPMENT

ENVIRONMENT 3 3 9

DAILY INSPECTION OF EQUIPMENT FOR

LEAKS

2 1 2 YES

PLANT & EQUIPMENT WILL BE CHECKED &

MAINTAINED IN A SAFE CONDITION

MAINTENANCE PERFORMED BY COMPETENT

PERSONS

DRIP PANS AND SHEETS USED DURING

SERVICE

SPILL KIT WILL BE AVAILABLE ONSITE IN

ADDITION TO MOP UP ANY ACCIDENTAL

SPILLS TO GROUND

SPILLS TO BE REPORTED IMMEDIATELY




Risk ALARP

DIP TRAYS TO BE PROVIDED AS TO HANDLE

ANTICIPATED SPILLAGE OR CONTAINMENT

REQUIREMENTS

IMPERVIOUS MATERIAL UNDER FUEL TANKS

WORKING ON

MEWPS

CHERRY PICKER

("BASKET CRANE'') -

PERSONNEL AND OR CHERRY

PICKER STRUCK BY VEHICLE

OR THE EXTENDED BOOM,

MATERIALS AND PERSONNEL

FALL FROM HEIGHT

4 3 12

TRAINED, COMPETENT OPERATOR AND

RIGGER (FOR HELPING OPERATOR WITH

BLIND SPOTS) TO CONTROL HIM SHALL BE

APPOINTED

2 1 2 YES


AND SIGNED (KEEP OUT AND LIFTING IN

PROGRESS)

SAFETY OFFICER IN SITE TO ENSURE DAILY

INSPECTION OF EQUIPMENT, PERIODIC

MAINTENANCE AS REQUIRED

SAFETY HARNESS/FALL ARRESTORS TO BE

USED BY PERSONNEL ON AERIAL PLATFORM

(BASKET)




Risk ALARP

OPERATOR TO FOLLOW THE EQUIPMENT

LIFTING CHART RESTRICTIONS, MAX. BOOM

RADIUS, PERSONNEL NUMBER AND WEIGHT

TO BE LIMITED ON BASKET ACCORDING TO

EQUIPMENT SPEC. - LIFTING PLAN TO BE

AVAILABLE PRIOR USE


PROHIBIT UNAUTHORIZED PERSONNEL .

CHERRY PICKER TO BE LOCATED ON

LEVELLED SURFACE & OUTRIGGERS TO BE

FULLY EXTENDED & PLACED ON PACKING.

HANDRAILS, MIDRAILS & TOE BOARD ON

BASKET (MINIMUM REQUIREMENT FOR

EQUIPMENT USE)

DAILY INSPECTION TO BE CARRIED OUT BY

COMPETENT MECHANIC/OPERATOR

LIGHTING OF 30LUX AND 3.0 FOOT CANDLE

TO BE PROVIDED

TUNGSTEN HALOGEN LIGHTING TO BE USED

WHEREVER POSSIBLE TO MINIMISE FIRE

HAZARDS CAUSED BY TUNGSTEN LIGHTING




Risk ALARP

BULB TO BE PROTECTED FROM BREAKAGE

AND ANY BROKEN OR DEFECTIVE BULBS TO

BE IMMEDIATELY REPLACED

LIGHTING FIXTURES TO BE POSITIONED TO

MINIMISE WORKER CONTACT WITH FIXTURES

DURING WORK OPERATIONS

LIGHTING SUPPLY CORDS AND CABLES TO

BE INSTALLED IN CONSISTENCY WITH GOOD

ELECTRIC WIRING PRACTICES.

ALL POINTS OF ACCESS AND EGRESS SHALL

BE CLEARLY ILLUMINATED AND MARKED

PORTABLE GENERATOR TO BE GROUNDED

AT OVER 3.0M DEPTH, METAL CASE SOCKETS

OF BULBS TO BE GROUNDED



Criteria ( C ) Consequence: Negligible- immediate return to work

Minor - first aid and return to work.

Moderate- medical treatment/ lost time

Major- multiple injuries and

RIDDOR reportable

Fatal/Catastrophic- Death, loss of

installation

Criteria ( L ) Likelihood:

Improbable- so unlikely that it would not

happen.

Unlikely- remote chance of event Possible- inattention may cause an

event to happen.

Probable- highly likely without control.

Certain- will happen without

Intervention / control.

Risk Calculator, Risk level R= C X L 1-4 Acceptable 5-8 Tolerable 9-10 Moderate 12-15 Substantial >15 Intolerable

Conclusions: Overall risk - Low/Medium Are risks reduced to ALARP (as low as reasonably practicable), Yes

Likelihood→ Consequence↓

Improbable 1

Unlikely 2

Possible 3

Probable 4

Certain 5

Negligible 1 1 2 3 4 5 Minor 2 2 4 6 8 10 Moderate 3 3 6 9 12 15 Major 4 4 8 12 16 20

Fatal/catastrophic 5 5 10 15 20 25 Overall risk. 1-4 =Low; 5-10 = Medium; 12-25=High

Appendix B

Insert for temporary support layout

Appendix C

Insert for temporary support detail

Appendix D

INTERFACE TC AND PROCESSOR

Construction InterfaceBetween

Transportation Center 422and

Processor (PTB) 421

7 August 2012

OBJECTIVE

Installation of Structural Steel Elements (Banana Trusses) at the Façade of the Processor of PTB Opposite Transportation Centre Without Compromising Completion Dates of Either Facility.

Outline Construction Schedule of Affected Facilities / Element

Aug Sept Oct Nov Dec Jan 13 Feb 13 Mar 13

Apr 13

Processor Concrete Level 2

XX XXX

Processor Concrete Level 3

XXXX

Transport Centre Roof XXXXX

Pedestrian Bridges XXXXX XXXXX

Automatic Walkway Bridges from MSCP

XXXXX XXXXX XXXXX

Structural Steel (Middle) XXXXX

Via Duct Decks Zones 2 & 4

XXXXX XXXXX XXXXX XXXXX XXXXX

Considered and Discarded Schemes for Installation of Banana Trusses

• Scheme 1: Crawling along the Façade

• Scheme 2: Two additional Heavy‐duty Tower Cranes

Outside the TC

• Scheme 3: Factory Cutting of Banana Trusses into 2‐3 ton

Segments

Scheme 1Crawler Crane along the Periphery

150 ton Crawler Crane lifts assembled upper two parts of banana Trusses (16 to 23 ton approx) and crawl with them along the periphery of the Façade to where they will be finally installed .

ProblemPostponing most activities on Curbside VD, TC and Bridges till after Façade works. Not acceptable phasing

Crawling along the Periphery

Scheme 2Two Additional Tower Cranes

• Two heavy‐duty tower cranes on either side of TC to install

banana trusses opposite to it.

Problem• Clash with Tower Cranes in Processor

Scheme 2 Operational Clash Diagram

Scheme 3Factory Cut into Shorter Segments

• Cutting Trusses into 2‐3 ton segments at factory and reassemble at final location (welding)

Problem• Result in 8 pieces and 7 Joints. Each will need to be supported

individually resulting in massive volume of temporary support. Involves multiple handling and on‐hook holding for longer time.

• More time and efforts as well as being esthetically inferior.

Load Contours of Tower Cranes at Processor

Proposed Scheme

Install Two All‐Terrain 500 ‐750 ton Telescopic Crane on either side of

Transportation Centre

– Transport assembled Truss from assembly yard on specially adapted flat bed trailer (26m long) to be lifted by 500‐750ton telescopic crane to its final location at the middle façade.

OR

– Transport the two parts separately and assemble on adjacent deck of Kerbside Via Duct. Lift to location as before (require shorter trailer)

NOTE: Added Advantage: Dismantle TC Tower cranes by

the All Terrain Telescopic Crane

Operational Radii for One Side of Middle Banana Trusses (East)

Typical All TerrainTelescopic Crane

Access and Space Details

Overhead Installations and Headroom Verifications above Access Route

East

Overhead Installations and Headroom Verifications above Access Route

East

Needed Scheduling Adjustments

Aug Sept Oct Nov Dec Jan 13 Feb 13 Mar 13 Apr 13

cessor crete Level 2

XX XXX

cessor crete Level 3

Remove Garbage Sorting Area and Concrete Delivery Stations

XXXX

nsport Centre Roof XXXXX

estrian Bridges and kways from MSCP Execute Piles and Footings ONLY

XXXXX XXXXX

omatic Walkway ges from MSCP

XXXXXXXXXXXXXXXSuper Structure (Decking)

ctural Steel (Middle sses)

‐Prepare Lifting Plan‐Prepare Access Road Layers

XXXXX

Duct Decks es 2 & 4

XXXXX XXXXX XXXXX XXXXX XXXXX XXXXXXXXXXXExecute Decks

General Layout around Processor

STAGE 4 ROOF and FAÇADE STRUCTURES _ REV 01_ WBS

• STAGE 4 ROOF and FAÇADE STRUCTURES _ REV 01_ PROPOSAL

EXTRACT FROM MST_ rev 02 STEEL ROOTS



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Water

tank

Water

tank

Water

tank

Water

tank

Water

tank

Water

tank

Water

tank

Water

tank

Water

tank

Water

tank

Water

tank

Water

tank

Water

tank

Remark: Zone F、G、D each need four water tank, Zone B、C、E、H each need two water tank

5548

70

65

88

75 1

73

08

11

20

9

25

63

0

36000 3600035514

1105555466

54

97

9

10946

16

42

59

25

9

21

09

6

23

66

0

46

29

382652

R

1

5

0

0

0

7

3

8

4

4

6

8

6

6

8

5

1

8

8

0

Assembly Yard

52

41

0

24945

7

1

5

2

9

52

41

0

500t Crawler crane

Scope of work

50t Crawler

crane 2 PCS

Temporary road

Temporary road

Temporary road

80

00

8149 8000 8796

80

00

R

1

5

0

0

0

4

5

5

9

1

500t Crawler crane

Scope of work

Assembly Yard

50000

25

00

0

50t Crawler crane 2 PCS

45

83

R

1

5

0

0

0

7

3

8

4

4

6

8

6

6

8

5

1

8

8

0

Assembly Yard

52

41

0

24945

7

1

5

2

9

50t Crawler

crane 2 PCS

Temporary road

Temporary road

Temporary road

80

00

814980008796

80

00

R

1

5

0

0

0

4

5

5

9

1

500t Crawler crane

Scope of work

Assembly Yard

50000

25

00

0

50t Crawler crane 2 PCS

45

83

10.1t

16.8t

16.72t

16.6t 22.3t

22.8t

22.2t

16.5t

16t

15.4t

15.5t

9.0t

15.3t

15t

17.6t

17.7t

17.9t

13.6t

13.3t

12.7t

12.5t

6.7t

11.6t

11.3t

14.3t

13.9t

13.2t

9.6t

9.3t

2.5t

16.8t

16.72t

16.6t22.3t

22.8t

22.2t

16.5t

16t

15.4t

15.5t

9.0t

15.3t

15t

17.6t

17.7t

17.9t

13.6t

13.3t

12.7t

12.5t

6.7t

11.6t

11.3t

14.3t

13.9t

13.2t

9.6t

9.3t

2.5t

500t Crawler crane500t Mobile crane

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Autodesk

Autodesk

Engineering

[03571] method statement for installation of steel structure