site erection manual

7/31/2019 Site Erection Manual

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SITE ERECTION MANUAL

1 PURPOSE

The purpose of this manual is to ensure that site erections are carried out according tospecifications and in a safe manner.

2 SCOPE

The scope of this manual shall include:

Basic sequence

Site organization

Erection Procedure

Quality control programme

Safety procedure

3 RESPONSIBILITYThe Site Engineer is responsible for the effective implementation of this manual on site andshall ensure that:

The workforce is aware of and implements the relevant standards and regulations.

Changes in procedures, which become necessary during the erection stages, are agreed byhim and/or design engineer, and that the technical document are corrected in order to be

consistent.

Hoisting equipment of suitable capacity is available for any preassemblies which must be

lifted.

Means of access, such as scaffolding, stairs and platforms, are installed to enable bolting

and welding to be carried out satisfactorily.

4 REFERENCE

Erection/assembly drawings

Loading/dispatch list

5 BASIC SEQUENCE OF ERECTION

The basic sequence for erection have been determined and documented for various projecttypes and are as contained in appendices A, B and C; and shall be strictly adhere to by

erectors on site.

6 SITE ORGANIZATION

Site shall be adequately identified and project signboard erected before commencement of

project.

Adequate supply of drinking water shall be provided in all places of works.

When sanitary sewers are not available, one of the following facilities, unless prohibited

by local codes, shall be provided: chemical toilets, recirculation toilets, combustion

toilets, or other systems as approved by state/local governments.

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Prior to start of work, arrangement shall be made for medical facilities and personnel to

provide prompt attention to the injured and for consultation on occupational safety andhealth matters.

All projects, activities, installations, or contracts at the site of work where neither a first-

aid station nor medical centre is available, shall be provided with a first-aid kit.

All the restricted areas on site shall be clearly identified as such and all necessary PPErequired accessing such areas indicated.

Construction site shall have a muster point for headcount in the case of emergency.

7 ERECTION PROCEDURE

Delivery

A construction sequence relevant to the particular project shall be agreed prior to delivery of

any material to site, from which a delivery schedule shall be produced. Particular attention

shall be paid to the logistics of the erection process to prevent members being missed out,double handling of materials on site, trucks being under-utilized, and the positioning of steel

in the wrong location.

Delivery of the steelwork shall normally be in 30-tonne semi trailer trucks on just in timedelivery sequence in order to alleviate site congestion, and minimize double handling and on-

site damage.

For transport and delivery to site of bolts, nuts and washers the following shall be noted:

They shall be provided with adequate packing, sufficiently protected to avoid damage

during transport.

In the case of high strength bolts, both bolts and nuts shall be adequately greased.

Each package shall contain only one type of bolt, nut or washer of the same diameter,

length and quality. Each package shall be provided with a label, indicating the manufacturers mark, the type

(bolt, nut and washer), the quality and the number.

High strength bolts are indicated by coloured labels, according to the type and quality (4.6= green, 8.8 = red, 10.9 = blue)

Reception of Materials

Any damaged material, which should be repaired or returned, shall be separated immediately

after arrival and documented. The project engineer shall be informed, to allow him assess

what effect this might have on the construction programme.

Handling of MaterialsWhen handling individual members the following shall be noted:

Parts with different reference marks shall not be mixed or packed together.

On large or heavy parts the lifting points shall be indicated, including where possible the

location of the centre of mass of the component.

All parts that can be easily damaged shall be adequately protected during transport andhandling.

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Components in the storage area shall be kept off the ground, protected from damp and dirt

by means of sleepers or battens.

When using steel wire cables as lifting strings the following shall be noted:

Care shall be taken to ensure that the sharp corners of beams are packed with wood in

order to protect the sling, the surface treatment and any prepared edges. Slings shall be regularly inspected, and the maximum safe load shall be shown on a steel

tag.

When using double-leg slings it shall be appropriate that the lifting capacity diminishes asthe angle between the legs increases. The Site Engineer shall ensure that the load in the

legs shall not exceed that calculated from

R = P x 1

2 cosa

Where R is the load in a leg, P is the total leg and is the half-angle between the legs of

the sling.

Maximum safe load shall not exceed 1/6 of the breaking load of the steel wirecable from which the sling is made.

The hoisting slings shall be regularly inspected and taken out of service as soon asthe number of broken wires in a metres length reaches or exceeds 20% of the total.

The slings shall not be bent over diameters less than six times the diameter of the

cable. If necessary rounded cushions shall be put in place to support the sling.

Regarding the storage and use of welding consumables, the following shall be noted:

The electrodes shall be packed in closed and sealed packages or tins; storage shall be in

closed and dry place to prevent condensation and special care shall be taken to avoiddamaging the coating.

When basic-type electrodes are used, they shall be dried or baked in accordance with thewelding procedure.

Once the sealed packets have been opened, the electrodes shall be placed in a portable

drying oven.

Mobile drying ovens shall be provided with an insulated quiver in which he keeps theelectrodes, taken from the nearest drying oven.

In very special cases and in very damp conditions the welders shall be provided with

individual portable drying ovens, from which they remove the electrodes one by one, asthey need them.

For general purpose a complete list of erection element shall be available on site indicatingtheir code-mark, weight, and size and specifying the locations where they will be used.

Foundations Levelling and Measuring

An inspection of the foundation, to check the levelling and alignment of the anchor bolts,shall be made before erection commences. A fixed levelling point and three fixed alignment

points shall be established for this purpose. Errors in the foundation identified at this stage,

shall be corrected using packer plates.

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The foundations shall be cleaned prior to erecting the steelwork. We shall ensure that the

cavities for holding down bolts are completely free from contamination.

Assembly and ErectionQuestions concerning the construction sequence and its effect on stability shall be resolved.

The designer shall position the braced bays in a way that they shall be the first to be erected.

The structure shall be braced and true as the erection proceeds.

Works at a height shall be minimized by the use of sub-assembly units where practicable.

Where sub-assembly shall be carried out on site, it shall be done behind the lifting equipmentin order that the assembly can be lifted straight off the ground and into position.

During lifting damage shall be minimized on the paint treatment by the use of softwood

packers and to ensure that the load will not slip as it is being lifted and that the sling-chains or

wires are not damaged.

Where the structure needs additional rigidity during erection temporary stiffening shall beused to ensure the rigidity of structure until the permanent connections are made.

Where a particularly awkward or heavy lift has to be made, special cleats shall be fabricatedfor this purpose.

Bolting Connections on Site

Before carrying out any bolted connections checks shall be made to ensure:

The bolts, nuts and washers to be used shall be exactly as indicated on the drawings.

Bolts, nuts and washers shall be cleaned and undamaged.

The parts to be connected shall be cleaned and without defects.

In connections with tapered flanges, tapered washers shall be placed under the nut, the bolt, or

both.

In the case of a hole with a vertical axis, the bolts shall be inserted from above, with the nut at

the bottom.

Welding Connections on Site

Where welding is necessary on site, careful pre-planning shall be required as follows:

Provision shall be made for temporary alignment of the adjacent components which are tobe welded together, and to hold them in position until they are welded. The methods

adopted for the alignment shall be able to carry the weight of the components and in some

cases a substantial load from the structure.

Safe means of access and a secure working platform shall be provided for the welder and

his equipment.

All welding shall be carried out by qualified welders in accordance with approvedprocedures.

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The earth return of the electric current must be made through the steel structures, cranes,

or through metallic parts of installations but must be directly connected to the constructionpart being welded.

The surface of zone to be welded shall be clean and dry.

Painting

Surface Preparation

Where oil and grease are present remove in accordance with the SSPC Surface

Preparation Specification using No. 1 Solvent Cleaning (SSPC-SP1). Perform cleaning

prior to blasting. If contamination remains after blasting, reclean with solvent

Blast cleans all steel to a commercial blast condition, as defined in SSPC-SP 1085equivalent to grade Sa2 of Swedish Standards SIS 05 5900 and Second Quality of

British Standards 4232.

Mixing Paint

Mix the primer with a high shear mixer in accordance with the manufacturersrecommendations to smooth, lump free consistency.

Mix in the original containers.

Continue mixing until all of the metallic powder or pigment is in suspension.

Assure that all of the coating solids that might settle to the bottom of the container are

thoroughly dispersed.

Mix each subsequent coat to achieve and to maintain a homogenous mixture.

Strain the mixture through 500m - 250 m (30-60 mesh) screen openings to remove

large particles.

Equip paint containers with a mechanical agitator so the mixture is in motion throughout

the application period.

Thinning Paint

Thin the paint only as recommended by the manufacturer.

Conditions for Painting

Apply paint only on clean and dry surfaces and only during periods of favourable weather.

Do not paint when the temperature of the air, paint, or metal is below 5C, and at no timebelow that described in the technical data sheet; when the air is misty; or when conditions

are otherwise unsatisfactory.

Do not paint damp or frosted surfaces or surfaces hot enough to cause the paint to blister,

to produce a porous paint film, or to cause the vehicle to separate from the pigment. Paint only when the surface temperature is at least 3C above the dew point. Determine

the dew point with the use of a psychrometer and psychrometric tables.

Allow each coat of paint to dry before applying the succeeding coat. Follow the

manufacturers recommendations for drying time, unless a longer drying time is required.

Application

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The erection has not deviated from the design requirements or specification without all

changes being approved by the appropriate body and a full record kept of those changes.

The method of construction have allowed for process quality control of welding, heat-

treatment of welding, non-destructive testing, alignment and plumbing.

Non-conformance ProcedureAll variations after the work has started shall be accompanied by a Non-Conformance Report

(NCR), traceable throughout the entire process and signed off by the design engineer.

Any damage or discrepancy shall be reported using the NCR system (appendix D) and

repaired or replaced following this approved system.

9 SAFETY PROCEDURE

Safety of the workforce

Every individual working on site shall take responsibility for safe work practices, regardlessof job title. Safety is everyones responsibility.

Before start of work, all workers shall attend a structural steel erection best practice review

for the project.

Weekly safety meetings shall be held and the sub-contractor shall be kept informed, in

writing, about discussions and issues that may affect safe erection of steel (e.g., weather

conditions [such as wind], access, and site conditions).

Workers Orientation

Prior to starting work, every worker shall attend a site orientation to be informed of andbecoming familiar with:

Site rules and regulations

Erection plan and procedures

Equipment to be used

Hazard assessment

Work area and emergency procedures (including the rescue plan)

Work areas of other trades and the need to communicate planned work activities to them

when working in close proximity

Personal Protective Equipment (PPE)

Employers and workers shall ensure that this equipment is used whenever a worker is

exposed to the relevant hazard.

All PPE shall comply with international standards.

Additional PPE are to be supplied as required for various tasks.

Hard hats should be worn reversed only if they are specifically designed and approvedby the manufacturer for that purpose.

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Trouser legs and laces must be tied or taped to avoid tripping hazards.

Lifting and Handling Loads

Manual handling of loads or materials by workers should be minimized.

Sub-contractors must provide, where reasonably practicable, appropriate equipment to

help workers lift, lower, push, pull, carry, handle, or transport heavy or awkward loads.

Housekeeping

Store all supplies, such as bolts in proper containers and set away from areas wherethey can pose tripping hazards.

Do not leave loose bolts and nuts lying on steel or on ground.

Perform ongoing cleanup as required.

Do not string hoses through high traffic areas or stairs. Instead, hang the hoses up to

eliminate the hazard.

Steel Fabricators Responsibility

The steel fabricator shall be responsible for:

Providing detailed connection information to ensure that the structure can be safelyerected.

Providing, where required, safety attachments or anchor points.

Steel Erectors Responsibility

The steel erector shall be responsible for:

Ensuring workers are adequately qualified, suitably trained, and with sufficient experience

to safely perform the assigned work.

Inform the company about access needs to the site specific work areas.

Pre-planning work activities to ensure that workers are not required to work under unsafeor suspended loads.

Developing site-specific work instructions and procedures that identify access and area

needs

Ensuring that requirements for moving loads over working areas are met. The erectormust comply with the general and specific requirements of lifting and handling loads.

Structural Steel Assembly

Installing Columns

Columns should be set on levelling plates, levelling nuts, shim packs, or level finished

floors for adequate transfer of construction loads.

Attach the column rigging through a bolt hole in the top of the column in the web or abeam clip. If the column rigging cannot be attached to the column due to the shape of the

column, then a choker may be used provided that a way to prevent the choker from slidingup the column is in place.

Signal the crane to lift column. Adjust the cranes line (by signalling the operator) to

remain above the column rigging (pick point) of the lift as column is being raised.

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Once the column is lifted off the ground and the crane has the complete weight, stop

the lift until the load settles (if required). Once the load settles, proceed to signal the craneoperator to move the column into position.

Lower the column:

o Placing columns on anchor bolts. Watch for pinch points. Once the base

plate of the shims touches the connection point, put the washer and nuts on the anchorbolts. Plumb the column by tightening the anchor bolts.OR

o Placing columns onto a steel column or beam. Watch for pinch points. Once

the base plate of the column touches the connection point, bolt down. Plumb the

column by tightening the connection bolts. Use spud wrench/sleaver bars to guide thecolumn into position. Use a minimum of 4 bolts to secure the column.

Release the weight of the column from the crane.

Before releasing the rigging, make sure column is secure on the anchor bolts.

Unstable columns must be guyed or braced as necessary.

Installation of Beams on Columns

During the final placing of solid web structural members, the load shall not be

released from the hoisting line until the members are secured with at least two bolts per

connection (of the same size and strength as shown in the erection drawings) drawn upwrench-tight or the equivalent as specified by the project structural engineer record.

A competent person shall determine if more than two bolts are necessary to ensure the

stability of cantilevered members; if additional bolts are needed, they shall be installed.

Solid web structural members used as diagonal bracing shall be secured by at least onebolt per connection drawn up wrench-tight or equivalent as specified by the project

structural engineer of record.

Double Connections

When two structural members on opposite sides of a column web, or a beam web over

a column, are connected sharing common connection holes, at least one bolt with itswrench-tight nut shall remain connected to the first member unless a shop attached seat

or equivalent connection devices is supplied with the member to secure the first member

and prevent the column from being displaced.

If a seat or equivalent devices is used, the seat (or devices) shall be designed tosupport the load during the double connection process. It shall be adequately bolted or

welded to both a supporting member and the first member before the nuts on the shared

bolts are removed to make the double connection.

Structural Stability

Ensure that structural stability is maintained at all times.

Construction loads must not be placed on any structural steel unless such framework

is safely bolted, welded, or otherwise adequately secured.

When used, temporary bracing must be in place and properly installed in conjunctionwith the steel erection plan to ensure the stability of the structure.

Temporary bracing can be removed only with approval of competent person.

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Rigging

Careful consideration must be given to the ground conditions and the soil compaction

in areas in which cranes are to be moved and operated.

If work is to be done or equipment is to be operated in the area of an energized

overhead power line, the employer must contact the power line operator to determine thevoltage of the power line, which determines the safe approach distance. Until the power

line operator verifies the voltage, the employer must maintain a safe clearance distance.

On cranes operating with outriggers, the beams must be extended with the pads down

according to manufacturers recommendations. The ground should be checked

periodically for settling, and the outriggers reset if necessary.

The maximum load rating is not the breaking strength of the piece of rigging. Anerector must ensure that the load rating of the piece of rigging is appropriate (5 to 1 for all

below-the-hook lifting devices; 10 to 1 for hoisting of personnel).

The maximum load rating must be marked on the rigging. If making the rigging is notpossible the load rating should be available to workers on site.

Slings must be checked before each use by workers. Damaged slings must be permanently removed from service.

Fall Protection

Workers must use a fall protection system if they may fall 3m or more, or if there is an

unusual possibility of injury if a worker falls less than 3m (e.g., falling unto exposed rebarpointing upward).

Workers working on flat roofs and workers engaged in connecting structural membersof a skeleton structure are not exempted from using a fall protection.

A fall protection plan must specify the:

- Fall hazards at the work site.

- Fall protection system to be used at the work site.- Procedures used to assemble, maintain, inspect, use, and dismantle the fall protection

system.

- Rescue procedures to be used if a worker fall or is suspended by a personal fall arrestsystem or safety net and needs to be rescued.

Review fall protection plan, including the rescue plan, with workers.

Working at Heights

Foreman can exercise judgement and shut down all work at his or her discretion due to

wind, rain or any other unusual weather condition.

Materials must be hoisted using material lifts or ropes and must be secured to preventfalling off steel. Do not carry materials up ladders.

Tools must be hoisted using material lifts or ropes and, when the tools are not in use, they

must be secured to prevent falling off steel or from being removed. Do not carry tools upladders unless the tools are part of a tool belt.

Secure and mark covers over open holes.

Install handrails and kick-plates in conjunction with stair and grating erection, whererequired.

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All materials, equipment, and tools that are not in use while aloft must be contained,

restrained, or protected from falling.

Erectors must protect workers from being struck by falling objects (e.g., an overhead

safeguard strong enough to withstand the shock load of falling objects), or if workers

enter into the danger area, then barricades, warning or signs can warn workers of the

hazards. Construction processes below steel erection must be prohibited unless overhead protection

for workers below is provided.

Safety net can be used to protect workers from falling objects.

Tools

Use of Hand Tools

Use all hand tools for the purpose intended by the manufacturer.

Use the right tool for the right job.

Inspect all tools for defects prior to use.

Prevent all hand tools from falling (where applicable) by using items such as lanyards,netting, and chains.

Use of Power Tools

Power tools must be used in accordance with manufacturers specifications.

Inspect all power tools prior to use.

Ensure all guards are in place.

Take damaged tools out of service and tag them for repair

Use proper personal protective equipment (PPE) while operating power tools

Ensure portable magnetic drills are tied off and equipped with lock-tight cord ends.

Prevent all power tool from falling (where applicable) by using items such as lanyards,

netting, and chains.

Cutting/Burning/Welding Operations

Secure compressed gas cylinders in an upright position and protect them or locate them

away from falling objects.

Oxygen fuel systems required a flashback arrestor and a back-flow prevention devices

A back-flow prevention devices is unnecessary in the fuel line of single-line torch systems

operating on fuel gas and aspirated ambient air, since the potential for creating anexplosive or flammable gas mixture in the hose does not exist (e.g., tiger torch).

Remove combustible material from area, if possible.

Use fire blankets where required.

Assign fire watch where required. Workers exposed to an airborne contaminant or mixture of contaminants must wear

appropriate respiratory protective equipment.

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site erection manual

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