Documents Transmittal Sheet

(DTS)-1111

PO No. 0287
PROJECT: Ithra Mapping Project / Technical Design
Package P.3
To: Ebenezer O. Gimpison Date : 15/04/24
Technical Support Division, Utilities Unit Our Ref : Whatsapp
King Abdulaziz Center for World Culture Date : 15/04/24
Tel: +966 13 8169135.

CC: abdulrahman.alshehri.8@aramco.com From : DGGC

ebenezer.gimpison@aramco.com P.O. Box No. : Alkhobar
Name : Mohammad Ghazi
Position : General Manager
Telephone : +966568862879
Email : mohammed@ksadgc.com

Drawings/Data Sheet Material/Equipment X Method of Statement

Design Protection/Control Telecom/SCADA

Electrical Civil Mechanical

S.No. Document/ No. of Rev Document Title Status Approval Stage

Drawing No. pages

Method statement for

01 MOS 111 11 00 steel structure 1
fabrication and Erection
Approval
Status Approval Stage Approval Date
Status
1 For Approval A Approved
2 Approval for Construction B Approved Except as Noted
FI For Information C Not Approved Revise & Resubmit `
AS For As Built D Rejected
Complying with scope of work and Technical Specification?

X Yes No

If (No) provide justification and attach supporting documents as per contract deviations

NOTE: Acceptance does NOT release the contractor from his responsibilities in performing the work in strict conformance with contract scope of work
and technical specifications
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INDEX
1.0 SCOPE OF WORK

2.0 PROGRAMME

3.0 MATERIALS

4.0 METHOD & SEQUENCE OF THE WORK

5.0 ERECTION

6.0-DIMENSIONAL INSPECTION

7. PROTECTION

8. PACKING AND DELIVERY

9. INSPECTION AND TEST PLAN

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1.0 SCOPE OF WORK

The purpose of this procedure is to describe the fabrication methods, welding techniques, quality
assurance and quality inspections to be carried out about welding, weld repair and weld inspections
for DGGC

2.0 PROGRAMME
Programme for Fabrication works refer to DGGC Structural Steel works Programme.

3.0-MATERIALS
3.1 Material Supply
The quality of materials should be according to Customer specifications and drawings. The Grade of
structural steel shall conform to European Standard EN 10025 as noted on the drawings with minimum
yield strength as specified below:
The steel shall be free from loose mill scale, surface defects, flaky rust, slag inclusions, laminations,
pitting and be of full weight or thickness within tolerances specified in standard.
Approved Steel suppliers will be used. As a normal practice mill certificates will be made available for
steel ordered. Substitution if any, on sizes or quality shall be implemented only after obtaining approval
from the Owner / Engineer.
All steel supplied shall be stored in a safe condition with proper care taken during storage to ensure
that no damage occurs, which renders the materials unserviceable.
All steel material shall be stored at the shop/yard above the ground on the platforms, skids or concrete
blocks.
Materials for this project shall be marked differently from the other project material. The identifying and
marking system shall be established. All steel material procured shall be properly documented to
ensure conformity to specifications and it shall be the responsibility of the control foreman or staff to
ensure conformity of steel to the specifications.
3.2. Material Identification and Traceability

Fabrication of all Structural and Miscellaneous Steel shall be as per 12-SAMSS-007 requirements.
After receipt of raw material, the warehouse responsible shall verify the material and forward the Raw
material inspection report to quality acceptance. Project Engineer will inspect the raw material and
verify the heat number correlation and material specification. On acceptance, Quality staff will give a
Material Code number for punching as per Identification and Traceability Procedure. Refer Project
Quality Plan.

The Fabrication Engineers / Foreman shall be responsible to arrange to mark the Item number and
punch the material code number on each member.
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4.0 METHOD & SEQUENCE OF THE WORK
Fabrication
The fabrication of steel works shall be carried out as per approved drawings and specification provided
by DGCC. The method and sequence of fabrication is given in the following chapters.
4.1 Fabrication Process
4.1.1 Cutting Plans
The cutting plan shall be prepared for all material before commencement of fabrication work. Material
mark number shall be provided for easy identification.
4.1.2 Marking
Marking shall be carried out as per approved cutting plan under the guidelines of fabrication foremen,
and subsequently verified by the Fabrication engineer prior to cutting. Prior to marking the material
shall be checked for its identification and the defects. Necessary items shall be carefully and
accurately marked in accordance with approved shop drawings or templates.
4.1.3 Cutting
Material cutting shall be carried out either by shear, plasma, CNC Profile cutting and drilling machine,
pug cutting machine. The edges of all plates shall be perfectly straight and uniform throughout. Cut
edges shall be visually examined for laminations and inclusions. All corners shall be shaped so as to
be notch free, sheared or cropped edges shall be dressed so that they are free from distortion and

burrs. Edge preparations for field welding shall be done in the shop
4.2.4 Cutting of Heavy Section:
The relevant standard rolled shapes or plate’s thickness exceeding 50 mm before cutting pre- heating
(Min 660C) shall be used. All cut edges shall be free of sharp notches and gauges.
4.2.5 Straightening
All steel material shall be straight and free from bends or twists. If the sections are distorted or twisted
during transit, storage etc. they shall be straightened and/or flattened by straightening machine at
ambient temperature, though minor bends may be corrected by limited heating under supervision.

4.2.6 Bending
The bending of plates and sections to specially required shapes shall be done on an appropriate
machine.
4.2.7 Holes
Punching and or drilling shall be done accurately as per the drawings and burrs removed effectively.
Where several parts are to be connected to very close tolerances, such parts shall be first
assembled, tightly clamped together, and drilled through. All holes shall be minimum 1.5mm larger
than the size of the bolt. The holes shall be drilled / reamed within the allowable limits specified in
Project specs. Holes for bolts shall not be formed by a gas cutting process except in special cases
with specific permission of the customer.
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4.2.8 Notches
The ends of all joints, beams and girders shall be cut truly square unless required otherwise and joist
flanges shall be neatly cut away or notched where necessary, the notches being kept as small as
possible.
4.2.9 Assembly
Structures shall be assembled in jigs or on suitable surfaces plates with proper layouts. The parts to
be joined groove welds shall be brought into correct alignment. The members to be welded shall be
held in the correct position by bolts, clamps, and wedges where practicable. Any wedges used to
space root gaps shall be removed from the root gaps immediately after tack welding and before making
the root run. After completion of joint fit-up, DGGC control or will check the fit-up and he will release
the joint for welding.
The fabricated components shall be assembled in such a manner that they are neither twisted nor
otherwise damaged. To minimize distortion in a member the components shall be positioned by using
clamps, clips, jigs and other suitable manner and fasteners shall be placed in a balanced pattern.
If necessary, items like roof trusses shall be trial assembled as per approved assembly drawing
keeping in view the actual site conditions prior to dispatch to site for erection, so that, they can be
conveniently preassembled before erection. Necessary match marks shall be made on these
components before disassembly in the shop and dispatching.
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4.2.9/10 Bolting
All bolt and nuts shall be used as per approved shop drawing and contract specification. Anchor bolt and
nuts shall be as per specification.

For construction Screws & Bolts should be Hot dip galvanized with Grade 8.8 or ASTM A325.

The marking of all Metal Products shall be as per 12-SAMSS-005 requirements.

4..2.9 Welding
Welding procedure qualifications and welders and welding operators’ performance qualification test shall
be made in accordance with BS EN ISO or relevant ASTM standards. Welding work will comply to AWS D1-
1.
4.2.9.1 Edge Preparation Inspection
The edges or surfaces of parts to be joined by welding shall be uniform, smooth, and cleaned from all
foreign materials such as moisture, slag, oil, grease, paint, scale or rust. Edge preparation shall be verified
for proper groove angle and root face dimensions. Welding groove dimensions shall be inspected as per
shop drawings under tack-welded condition prior to welding. The allowable misalignment of adjoining
plates to be butt-welded shall be in accordance with AWS D1.1or BS-EN- ISO.
4.2.9.2 Fit-up Assembly.
Erection of all Structural and Miscellaneous Steel shall be as per 12-SAMSS-008 requirements.

The Members or Plates to be welded are fit-up, aligned and retained in position to welding operations. The
location of integral parts / members to be assembled shall be checked dimensionally prior to full welding.
Tack welds shall be use for secure alignment. Generally, the tack welds shall be subject to the same quality
requirement as the final welds unless otherwise specified. Tack welds containing any cracks shall be
removed thoroughly and replaced with sound tack welds. Size and location of tack welds based on
Specification.
4.2.9.3 Backing Strip Inspection
Back-stripped surfaces shall be visually checked for root gap prior to start welding.
4.2.9.4 Welding Process
 The following practices shall be used for welding.
 Run-on and run-off plates shall be welded at the ends of welding lines of crucial butt welds.
 Prior to welding the surface to be welded and filler material to be used shall be checked.
 Prior to welding root opening, groove angle and the crucial dimensions shall be checked, and
groove face shall be free from oil, water, and dirt.
 Prior to welding the welding current shall be measured to the most appropriate welding condition
(current & voltage) and shall be maintained with ammeter and voltmeter throughout welding work.

 All welding is to be carried out in an approved environment and, if necessary, additional protection
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 may be required. All joints are to be dried before welding in damp climatic conditions.

 During welding work, the most appropriate arc length, angle, and welding speed shall be maintained
so that welding defects shall be avoided, and arc energy requirements are satisfied.
 Fillet weld terminating at the end of members shall be returned continuously around the corner for not
less than twice the size of the weld.
 Surfaces of butt joints required to be flush shall be finished so as not to reduce the thickness of the inner
base metal or weld metal than 1mm or 5% of the thickness whichever is the smaller not leave
reinforcement that exceed 1mm. All reinforcement shall blend smoothly into the plate surfaces with
transition areas free from undercut.
 Chipping and gouging shall be used, provided grinding follows them.
 In the case of multi-layer welding, slags and spatters on each completed bead shall be removed prior
to the start of welding for the following layer.
 All craters shall be filled to the full cross section of the welds.

4.2.10.4.1 Type of Welding Process

All Welding activities shall be carried out as per the approved Welding procedure specification.
The following Welding Process used in Fabrication works.

All Machinery used should be inspected and stamped with ARAMCO blue sticker ONLY.

All Operators, Riggers, Welders, Engineers etc.. Should be ARAMCO certified.

All Machinery used should be inspected and stamped with ARAMCO blue sticker ONLY.

All Operators, Riggers, Welders, Engineers etc.. Should be ARAMCO certified.

 SMAW Process
4.2.10.4.2 Electrodes
The electrodes used for welding shall be of suitable type and size depending upon specifications of the
parent materials, the method of welding, the position of welding and quality of welds desired. However,
only low hydrogen electrodes (E 7018) shall be used for plates and sections.

E70 series welding electrodes will be used only.

All low hydrogen electrodes shall be baked and stored before use as per manufacturer’s recommendation.
The electrodes shall be re-baked at 250 °C to 300° C for one hour and later on cooled in the same oven
to 100°C. From the baking oven the electrode shall be transferred to a holding oven maintained at 60° C–

70° C. The electrodes shall be drawn from this oven for use. Where coated electrodes are used they shall
meet the requirements of relevant BS-EN-ISO Standard, Bare Electrode and Granular flux conform to
relevant BS-EN-ISO Standard. Where Charpy V – Notch values are required on the base metal, an

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electrode meeting the requirement of BS-EN-ISO or AWS and having a minimum average Charpy V- notch
impact strength of 25 ft, lbs at –200c.

4.2.10.4.3 Preheat and Inter-pass Temperature

Preheating of above 65 degree C shall be applied for over 38mm thick of S355JR, JO, J2 and K2 steel
plate by means of oxy- acetylene flame or non-carbonizing like LPG. Uniform heating of the surface
extending up to a distance of three times the thickness of the plate on either side of the plate shall be
obtained. Preheating minimum 177 degree C shall be applied for relevant BS-EN-ISO Standard rolled
shapes or plates equal or grater than 50mm in thickness joined by partial or full penetration welds in tension
The specified preheat temperature and minimum inter-pass temperature shall be maintained during
welding progress. Thermo-chalk or other approved methods shall be used for measuring the plate
temperature.

Sequence of Welding (Control of Distortion and Shrinkage)

 The sequence of welding shall be selected to ensure that the components assembled by welding are
free from distortion and large residual stresses are not developed
 In assembling and joining parts of a structure or of built – up members and in welding reinforcing parts
to members, the procedure and sequence shall be such as will minimize distortion and shrinkage.
 In so far as practicable, all welds shall be deposited in symmetrical sequence so that shrinkage on both
sides of the structure will be equalized.
 Joints expected to have significant shrinkage shall be welded before joints expected to have lesser
shrinkage and with as little restraint as possible.
 All shop splices in each component part of a cover plate beam or built – up members shall be made
before such component part is welded to other components parts of the member.
 All welding shall be carried out continuously to completion or to a point that will ensure freedom from
cracking before the joints is allowed to cool below the minimum specified preheat and inter- pass
temperature.
 Butt weld in flange plates and / or web plates shall be completed before the flanges and webs are welded
together.
 The ends of butt welds shall have full throat thickness. This shall be obtained on all main butt welds by
the use of run off and run on pieces adequately secured on either side of main plates. Additional metal
remaining after the removal of extension pieces shall be removed by grinding or by gas cutting.
4.2.10.4.4 Visual Examination of Welds

Each reinforcement height for butt welds and leg dimensions for fillet welds shall be checked in addition

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to bead contour appearance. Also, possible presence of such service defects, undercut, crack, surface
porosity etc. shall be checked visually. The reinforcement on each side of butt-welded joints shall be
checked in accordance with AWS D 1.1 or BS-EN-ISO
Temporary lugs, braces and clips shall be welded in connection with Welding proceedure and these shall
be removed without damaging the base metal and the area ground flash and smooth.
4.2.11 PROCEDURE FOR BUILT UP GIRDERS / BEAMS
4.2.11.1 Preparation of Material
Marking of steel shall be done in accordance with the shop drawings and cutting plan. Material cutting shall
be carried out by gas. Either by pug cutting or CNC machine to cut the plates to the required sizes. The
dimensions and shape of the edges to be joined by welding shall be checked as per approved drawing /
specification. Surfaces and edge preparation shall be free from loose scale, slag, grease, paint and other
foreign matter. Edge preparation shall be verified for proper groove angle and root face dimensions. Joint
surfaces shall be free from fins and tears.
Marking of all Metal Products shall be as per 12-SAMSS-005 requirements.
4.2.11.2 Fit-up Assembly
Built up Girder Structure shall be assembled in jigs or on suitable surfaces plates with proper layouts as
per the Drawing. Butt weld in flange plates and / or web plates shall be completed before the flanges with
web fit-up Assembly. The Flange Plates shall be fit –up with web plate, for correct alignment and held in
position by use suitable devices or by tack welds until welding is completed to assure the most suitable
welding position and accurate assembly. After completion of Flanges and Web joint fit-up, DGGC Controlor
shall be check the fit-up and release for welding.

4.2.11.3 Welding Process

Welding shall be carried out as per the approved Welding procedure specification (WPS) and welders.
Run-on and run-off plates shall be welded at the ends of the Girder / beam.
Before welding start, joints shall be preheated above 650c by means of gas flame to bring to the
specified preheat temperature in the full thickness of the base metal for a distance equal to the thickness
of the part being welded. (Thickness t > 38 mm) specified preheat temperature and minimum inter-pass
temperature shall be maintained during welding progress. The temperature shall be checked by thermal
chalk. The approved electrodes shall be used for welding as per WPS. During welding most appropriate
arc length, angle and welding speed shall be maintained so that welding defects shall be avoided.
In the case of multi layer welding, slags and spatters on each completed bead shall be removed prior to
the start of welding for the following layer. After completion of welding all Temporary lugs, Run-on and run-
off plates shall be removed without damaging the base metal and the area ground flash and smooth. All
welding area shall be clean and inspect as per specification. After completion of inspection and test for
girder release for further fabrication activities.
4.2.12.1 General Requirement Of Visual Inspection
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Weld Visual inspection shall be carried by Fabrication Engineers or certified Welding Inspector as per BS-
EN-ISO standard for external defects like, surface porosity, under cut, excess penetration, over laps, lack
of penetration or incomplete fusion and fillet sizes.
4.2.12.2 General Requirements Of Liquid Penetrant Testing (PT)
Liquid Penetrant Testing procedures shall be in accordance with ASTM E 165 or relevant BS-EN- ISO
Standard.This test shall be carried during the welding process while back gouging. The evaluation of
indications and the acceptance criteria shall be in accordance with Sec.VII Div.1 ASME code or relevant
EN-ISO standards.
4.2.12.3 General requirements of Magnetic Particle Testing (MT)
Magnetic particle Testing procedures shall be in accordance with ASTM E 709, AWS D 1.1 or relevant BS-
EN-ISO Standard. The evaluation of indications and the acceptance criteria shall be in accordance with
ASTM E 709, AWS D 1.1 or relevant BS-EN-ISO Standard. Independent testing authority MPI reports shall
be obtained for fillet welds.
4.2.12.4 General Requirements Of Ultrasonic Examination (UT):
The ultrasonic Testing of plates for lamination shall be in accordance with SA 435 and UT of Butt joint shall
be in accordance with ASTM E 164, AWS D 1.1 or relevant BS-EN-ISO Standard. Independent testing
authority UT reports shall be obtained for all butt joints.

5. ERECTION: -

a) Before start of erection all crane & Hydra & other lifting equipment's shall be ensured of having proper
test certificates so that it can work safely for the required load of the member.

b) Storing & Handling shall be done to avoid excessive stress & any damage.

c) The erection clearance for cleated ends of members shall be not greater than 2 mm at each end. The
erection clearance at ends of beams without web cleats and end plates shall be not more than 3 mm at
each end. Erection tolerances as per IS 12843.

d) Proper safety precautions shall be taken before & during the erection work each worker shall be trained
for precaution taken for erection jobs.

e) The framework must be sufficiently braced to prevent wind damage.

f) Steelwork shall be hoisted and erected in position carefully, without any damage to itself, other works and
injury to workmen.

g) During erection, the steelwork shall be securely bolted or fastened. Wherever necessary temporary
braces shall be provided for all loads to be carried by the structure during erection, including those due to
erection equipment and its operation.

h) All field assembly and welding shall be executed in accordance with the requirements for shop assembly
and welding. A hole for all erection bolts were removed after final erection shall be plug weld. Alternatively,
erection bolts may be left and secured.
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i) A specific erection scheme with methodology shall be submitted to PMC. In case of criticality of
structures, equipment etc., the erection scheme shall be submitted separately.

j) During high wind velocity, ghai rope (wire rope sling) will be tied up at the column top at the time of
erection and full tightening of bolts & nuts in structural members after erection.

k) Erection inspection the structure shall be checked by the area In-Charge/QC for the following including
finish grade such as levelness, plumb-ness, etc. (Member installed, dimensional check, grade of bolt
and size, bolt tightening, paint repairs) A punch list shall be Prepared by the TEL Engineer

6. DIMENSIONAL INSPECTION
The fabricated steel structure shall be inspected in accordance with respective approved fabrication
drawings and specification. Over all length, orientation, diagonal measurement and all other dimensions
shall be verified and recorded. If dimensions are not with required tolerance the member shall be corrected
prior to further process. All dimensions shall be recorded in approved format. 100% visual inspection shall
be carried out for external defects. DGGC Quality staffs shall conduct the final inspection and review all
inspection reports and prepared as inspection and test plan (ITP).

7. PROTECTION

7.1 Hot dip galvanizing is the process of coating iron or steel articles with zinc by immersing the metal in
a bath containing molten zinc at a temperature of around 450°C.

During the process, a metallurgically bonded coating is formed which protects the steel. The majority of
galvanizing plants can accept a wide variety of shapes and weights of steel fabrication.

A small number of specialist plants are semi-automated or fully automated for galvanizing long runs of
sheet, wire or tubes and do not operate to BS EN ISO 1461.

Hot Dip Galvanizing Process

Stages of the Process

Degreasing

Chemical Cleaning

Flux Treatment

Drying

Galvanizing

Cooling and Checking

Results

Considerations before Hot Dip Galvanizing

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8. PACKING AND DELIVERY

The painted structures after fabrication shall be protected from further damage during transportation. The
materials will be loaded on to the trailers using timber supports and separators and secured properly to
prevent any damage to the material while transportation to site. Fabricated items will be delivered loose.
Minor fabricated items, which are not likely to be subject to permanent deformation during handling
operations (i.e. bracing etc) maybe bundled or hoped. Small items (i.e. bolts, loose, cleats etc) will be
packed in crates/drums or loaded on pallets.

9. INSPECTION AND TEST PLAN

Approved Inspection and test plan shall be implemented during each stage of fabrication, to ensure the
work is carried out with full compliance drawings and specification. The Inspection and approving parties
as per ITP shall ensure the quality of work at every level.

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