nae Psixconstruct nat cloao METHOD STATEMENT FOR STRUCTURAL STEEL FABRICATION AND PAINTI NG Passenger Terminal Complex CONTRACTOR'S VERIFICATION STAMP PURSUANT TO SPECIAL CONDITION 6, WE SIXCONSTRUCT ~ MIDMAC JOINT VENTURE VERIFY THAT THIS SUBMITTAL SATISFIES ALL REQUIREMENTS OF THE CONTRACT, WITH THE EXCEPTION OF THE FOLLOWING CLARIFICATIONS / PROPOSALS ACCEPTED BY THE ENGINEER. CONTRACTOR'S PROJECT DIRECTOR: ‘HANS JORG HIRSCHHAUSER ‘STATUS 1: WORK MAY PROCEED ooog ‘SIGNATURE DATE DOCUMENT REVIEW STATUS STATUS 2: REVISE AND RESUBMIT, WORK MAY PROCEED SUBJECT TO INCORPORATIN OF COMMENTS INDICATED STATUS 3: REVISE AND RESUBMIT, WORK MAY NOT PROCEED ‘STATUS 4: REVIEW NOT REQUIRED, WORK MAY PROCEED PERMISSION TO PROCEED SHALL NOT CONSTITUTE ACCEPTANCE OR APPROVAL OF DESIGN DETAILS, CALCULATIONS, ANALYSES, TEST METHODS, OR MATERIALS DEVELOPED OR SELECTED BY CONTRACTOR AND SHALL NOT RELEIVE CONTRACTOR FROM FULL COMPLIANCE WITH THE CONTRACT TECHNICAL SPECIFICATIONS AND DRAWINGS. Document No: 25045-A1100-51-3GS-S-02.0002 Rev 0 Issued by: SMV Rav | Date | Ravin | Sub-Cont: Eversendar Description ‘Checked by = IKCOMIDHAT IV ‘Approval ‘QNac Mgr HSE Mgr Const. Mar ‘Stretl. Mor Dep. Proj. Mar 0] 2508. | Tasued tor 10 | ApprovalNDIA New Doha International Airport Project METHOD STATEMENT FOR STRUCTURAL STEEL FABRICATION aE AND PAINTING @Fsixconstruct midmac ;', clLoao Document No. on 25045-A1100-51-3GS-S-02.0002 25.09.2010 Rev.0 | Page 2 0f 74 TABLE OF CONTENTS. |. TITLE. SCOPE OF WORK 2.4 General description. 2.2 Plant and equipment. 2.3 Materials. 2.4 Site planning & preparation 2.5 Work methodology. 2.6 Organization, Responsibilities & Supervision. 2.7 Work Force. HEALTH, SAFETY AND ENVIRONMENTAL (HSE) ISSUES: 3.1 Risk assessments 3.2NDIAE S &H Contractor Requirements 3.3 Protective & Safety Equipment 3.4 Contractual Requirements 3.5 Information to personnel. 3.6 Emergency Procedures. QUALITY ASSURANCE 4.4 Contractual Requirements 4.2 Critical works, 4.3 Inspection & Testing 4.4 Follow up & Evaluation. ATTACHMENTS, Annexure — A: Organization Chart ‘Annexure — B: Plant & Equipment List Annexure — C: Risk Assessment Annexure - D: Manpower histogram Annexure -E: Estimated Project Raw material Quantity Annexure -F: Briefing SheetaE AND PAINTING NDIA New Doha International Airport Project ‘Six Constru METHOD STATEMENT FOR + ce STRUCTURAL STEEL FABRICATION midmac |'| clloao Issue date: 25.09.2010 Document No. 25045-A1100-51-3GS-S-02.0002 Rev.0 | Page3 1.0 TITLE METHOD STATEMENT FOR STRUCTURAL STEEL FABRICATION AND PAINTINGmidmac |'; vlloao NDIA New Doha International Airport Project__| struct METHOD STATEMENT FOR ‘Prsucon Glu STRUCTURAL STEEL FABRICATION AND PAINTING Document NO. ee 25045-A1100-51-3GS-S-02.0002 Rev.o | Page 4 of 74 2.0 SCOPE OF WORK 2.4 General description The Scope shall include all labor, material, equipment, permits and services necessary for the fabrication and installation of structural steel and related work, complete, in accordance with the drawings and as specified herein including the detailing of all connections not completely designed on the contract documents, This method statement provides sequence and control of fabrication & Blasting and Painting of structural steel work, that are fabricated under control of EVERSENDAI ENGINEERING — Qatar, Dubai & Malaysia and other approved subcontractor fabrication shops prior to shipment / erection. 2.1.4 Reference Documents: 2.2 2.3 AISC - American Institute of Steel Construction AWS D 1.1 = Structural Welding Code ANSI 249.1 -1999 safety in welding SECTION 05120 Rev K- NDIA Project specification for structural steel and primer paint SECTION 05121 Rev A — NDIA Project specification for structural steel and primer paint ‘SECTION 05060 Rev J — NDIA Project specification for welding ‘SECTION 09805 — NDIA Project specification for Acrylic polyurethane system ASTM ~ American Society for Testing and Material EVS/QM/001 ~ “Quality Manual” ITP ~ Inspection and Test Plan PQP — Project Quality Plan WPS, POR&WOT All Approved drawings VV VV VV VVYY Plant and equipment. Eversendai Engineering having sufficient resources of Plant / Equipment to execute the contract works. Plant and Equipment list is enclosed in ANNEXURE -B Materials. All Raw steel materials shall be acceptance by Client. 2.3.1 Material Supply All steel materials shall generally comply with the relevant codes, standards and specifications listed in Contract Documents and Design Standards.NDIA New Doha International Airport Project ussrueatece| METHOD STATEMENT FOR Paxcone STRUCTURAL STEEL FABRICATION er GiJ AND PAINTING monec || close Document Ni pea 25046-A1100-51-8GS-5-02.0002 Rev.0 | Page sof 74 ‘The Grade of materials to be used for this Project shall be as follows: a) b) °) d) WF columns, WF Beams &Girders - “ASTM A992M OR ASTM572M GR345 FY=345Mpa or Equivalent BS S355JR Hollow structural sections (HSS) & - "ASTM A50OM, Fy=317 Mpa Rectangular & round shape or Equivalent BS S355J2H Angles, Channels, MISC& Shapes *ASTM A36M, FY=250Mpa or Equivalent BS $275JR Plates 1) Column base plates & all other plates not otherwise specified - “ASTM A 36, Fy=250Mpa 2) Plates above 50 mm thicker - * ASTM A5S72M OR AS88MGr.345 Fy=345Mpa 3) Column splice plate - * Match column grade 4) Continuity plates in beam, column and Frame joints - *Match column grade 5) Shear Tabs -*ASTM AS72M Gr.3 Fy= 345Mpa Estimated Raw material Quantity attached in annexure E (e) Bolts 1) Frame beams (No Slotted holes) *ASTM A 325M TYPE N 2) Non- frame beams * ASTM A 325M TYPE N 3) Anchor bolts & Columns* ASTM F1554 GR 105 / ASTM A364 Gr BD 4) All other bolts (where not noted) * ASTM A307 / ASTM F1554 GR 36 (f) Painting Material ‘As per PS 05120 Clause 2.3 - Primer :SSPC-Paint 25, Type 1, Iron oxide, Zinc oxide, raw linseed oil and Alkyd Primer for AESS — As per PS 9805 —Clause 2.2a -two component moisture cured zine rich urethane primer The steel shall be free from mill scale, surface defects, flaky rust, slag inclusions, laminations, pitting and be of full weight or thickness within tolerances specified in standard,NDIA ] New Doha International Airport Project SixConstruct | METHOD STATEMENT FOR nai STRUCTURAL STEEL FABRICATION $i GlJ AND PAINTING andres | clone Doct it Ne Inaue dete 25046-A1100-51-3GS-5-02.0002 Rev.0 | Pages ot 24 Approved Steel suppliers / Source will be used. As a normal practice mill certificates will be made available for the steel procured for this project. ‘Substitution if any, on sizes or quality shall be implemented only after obtaining approval from the SMJV/DGJ 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. 2.3.2 Material Identification and Traceability All materials shall be received from steel supplier and shall be conform to the requirements of the applicable standards and approved drawings. Mill test certificate of the chemical analysis and Mechanical properties of the material also shall be received along with material. After receipt of raw material Fabrication Engineer shall verify the material and forward the Raw material inspection report (EVS/FR/O10/02) to QA/QC acceptance. QA/QC Engineer will inspect the raw material and verify the heat number co relation and material specification. On acceptance, QA/QC Engineer will give a Material Code number for punching as per Identification and Trace ability Procedure. The Fabrication Engineers / Foremen are responsible to arrange to mark the Item number and punch the material code number on each member. Fabrication Planning & Preparation. Fabrication / Manufacturing will be undertaken at Eversendai Engineering Qatar / Dubai / Malaysia & other sub contractor fabrication facilities in accordance with the Quality Management System defined in the Company's Quality Manual (EVS/QM/001) and supporting procedures and or Contract specification. Fabricated materials will be delivered from the shops to NDIA site by road using Trailers & from Malaysia by sea.NDIA New Doha International Airport Project @Fisixconstruct METHOD STATEMENT FOR STRUCTURAL STEEL FABRICATION midmac ,', clloao GIJ AND PAINTING ‘Document No. Issue dato enue dat 25045-A1100-51-3G8-5-02.0002 ev.o | Page Tof74 2.5 Work Methodology. The fabrication of works shall be carried out generally in accordance with contract specification and fabrication drawings. All materials will be completely fabricated at shop and finished with proper connection materials for ready assembly in the filed. QC Dossier for fabrication, and trail assembly records if any will be submitted to the Client. The components shall be fabricated conform to the approved fabrication drawings. Welding Procedure (WPS), Procedure qualification (PQR) and Welder qualification (WOT) shall be qualified and should be approved by an independent inspection Authority. Pre-Fabrication and Fabrication of steel structures will be undertaken in accordance with the Contractor's approved Health, Safety and Environment Plan. The method and sequence of fabrication is given in the following chapters.NDIA New Doha International Airport Project GiJ METHOD STATEMENT FOR STRUCTURAL STEEL FABRICATION PFrsixconstruct | midmac \', vlloao AND PAINTING ‘Document No, Issue date: 25.09.2010 25048-A1100-51-3GS-S-02.0002 Rev.0 | Page 8 of 74 Fabrication Flow chart No Check IFC Drawing From DGJ Procurement of Material + Preparation of YT —— Material Receipts/ ¥ ———] Storage Preparation of Cutting Plan SSE eta Cutting / Drilling ¥ Assembly / Fit-up T Yes Inspection Welding Yes * Inspection / NDT Yes} Blasting / Painting 1 ve Inspection I Packing & DeliveryNDIA New Doha International Airport Project @Psuconsiruct METHOD STATEMENT FOR | STRUCTURAL STEEL FABRICATION te i ‘AND PAINTING metas || Leas De it N¢ eget 25045-A1100-51-368-5-02.0002 Rev.0 | Page 9 of 74 2.5.1 Fabrication Process (Procedure) 2.5.1.4 2.6.1.2 2.5.4.3 Preparation All fabrication drawings, issued as “For Construction” shall be carefully reviewed and Cutting Plans / Lists shall be prepared for each type and size of material to minimize wastage of materials. Components shall always be fabricated from the largest plates available, consistent with design requirements, to minimize the amount of weld joints unless otherwise required by the Engineer. Handling of the material shall be using suitable capacity slings or hooks and belts, approved by the related project standards. Proper protection material shall be used for lifting of coated/painted materials to avoid any damage that may be ocourred during handling. Cutting Plans The cutting plan shall be prepared before commencement of fabrication for all fabrication drawings. Planning department shall prepare cutting plan for raw materials cutting according to the drawings, These cutting plans will be issued to material control, production & QA/QC departments. Material control department will feed the relevant material to the production line for further process. The production department will carefully mark each and every member! .ce as per the drawing in line with cutting plan, Each piece will be stamped with mark numbers and the remaining piece will be transferred back to material department for storage. The stamped member / piece will then be taken for further process. Records will be maintained by Inspection department and this will be monitored throughout the process. Material mark number shall be provided for easy identification Marking Marking shall be carried out as per approved cutting plan under the guide lines of fabrication foremen, and subsequently verified by the Fabrication engineer prior to cutting. Activity shall be recorded in the in process Inspection register (EVS/FR/009/13) 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.GiJ NDIA New Doha International Airport Project METHOD STATEMENT FOR eo STRUCTURAL STEEL FABRICATION AND PAINTING midmac |") Issue date: 25.09.2010 Document No. 25045-A1100-51-3GS-S-02.0002 Rev.0 | Page 10 0f 74 Suitable allowance for shrinkage due to welding and margin for finish shall be taken into consideration. 2.5.1.4 Cutting Material cutting shall be carried out by gas. Either by hand or pug cutting / CNC Profile cutting machine. The edges of all plates shall be perfectly straight and uniform throughout cut edges shall be visually examined for laminations and inclusions. Cutting of Heavy Sections rolled or plates thickness exceeding 50mm; Preheating shall bbe applied not less than 66 degree C Surfaces prepared for welding shall be visually examined and checked by gauges to ensure freedom from laminations, cracks, slag inclusions and cutting notches. Any such defects shall be dressed out by grinding, If the depth of damaged area or crack exceeds 5 mm, a weld repair shall be made using a qualified WPS. The surface of the steel within 75 mm of the proposed weld shall be dry, clean and free from loose scale or paint. Flame cut edges which are not subsequently welded shall be ground smooth by grinder to remove nicks and burrs. All comers 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 ae Plate Cutting M/C.NDIA New Doha International Airport Project = A METHOD STATEMENT FOR a BEE STRUCTURAL STEEL FABRICATION AND PAINTING mines || clan Document No. ieie date 25045-A1100-51-3GS-S-02.0002 Rev.0 | Page ll of 74 25.09.2010 2.8.1.5 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.NDIA ] New Doha International Airport Project PF sixconstruct METHOD STATEMENT FOR fe STRUCTURAL STEEL FABRICATION | ts AND PAINTING midras || eLeae Issue date: 25.09.2010 Document No. 25045-A1100-51-3GS-S-02,0002 Rev.0 | Page 12 of 74 2.5.1.6 Bending The bending of plates and sections to specially required shapes shall be done either on appropriate machine or black smithy processes. 2.6.1.7 Holes Holes shall not be drilled in structural members other than at locations indicated on the fabrication Drawings, unless approved by the Engineer. 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 in diameter than the specified bolts. The holes shall be drilled/ reamed within the allowable limits specified in AISC / Project specs. Bolt type Diameter of the Bolt | Diameter of the Bolt hole (mm) | (mm) 20 22 ASTM A325 /A49088.8 24 26 Bolts 27 30 30 33 ‘Anchor Bolts Dia Dia +Smm Holes for bolts shall not be formed by a gas cutting process except in special case with specific permission of the customer and higher thickness plates. Wherever a horizontal member is likely to collect water suitable holes for drainage shall be provided, Base plate holes shall be done by drill, cut, mechanically thermal cut (Plasma cutting) and punch perpendicular to steel surface. 2.6.1.8 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, 2.5.1.9 Shop 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, clamp and wedges where ever 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.ort Project METHOD STATEMENT FOR asNE STRUCTURAL STEEL FABRICATION midmac Vi lors GiJ AND PAINTING | | Document No. Issue date: Ee 25.09.2010 25045-A1100-51-3GS-S-02.0002 Rev. 0 Page 13 of 74 After completion of joint fi-up, Eversendai QC Inspector 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 damaged and also shall be provide the specified chamber, if any is provided. In order to minimize distortion in a member the components shall be positioned by using clamps, clips, jigs and other suitable means and fasteners shall be placed in a balanced pattern, Proper welding sequence shall be followed to avoid distortion. If necessary Items like APM Track, Y-Column, Roof Trusses and box / plate girders etc. shall be trial assembled keeping in view the actual site conditions prior to dispatch to site for erection so that they can be conveniently erected at final position, Necessary match marks shall be made on these components before disassembly in the shop and dispatching. Necessary edge preparation for field welding shall be made and verified during assembly. 2.6.1.10 Shop Bolting All bolt and nuts shall be used as per approved shop drawing and contract specification, Bolts shall be tightened in accordance with tensioning requirements (snug tight or pretension) given in the related drawings. Bolt heads shall be tappedifixed with a ‘spanner while the nut is being tightened, Pretension tightening shall be carried out using a calibrated pneumatic torque machine / or DTI Washer and tested as per the requirement of the bolts grade and standard. 2.5.1.10.1 PREPARATION OF FRICTION JOINTS The surface of the member's friction connected with high strength bolts shall be cleared of mill scales and blasted in accordance with friction requirements. Friction surfaces shall be visually inspected Friction surfaces shall be masked off before painting and delivery to site. 2.5.1.11 Shop Welding (Welding Procedure) Welding procedure qualifications and welders and welding operators’ performance qualification test shall be made in accordance with AWS D 1.1 - 2008 / ISO 15614-1(BSNDIA New Doha International Airport Project PFsixconstruct METHOD STATEMENT FOR STRUCTURAL STEEL FABRICATION 1g GIJ ‘AND PAINTING audac 11 chong DO it N¢ Ton aid 25048-A1100-51-3GS--02.0002 Rev.0 | Page 14 of 74 EN 288 Part II) and Qualified by third-party .If existing WPS available, than that will be ‘he folowing documents shall be submitted to client prior to commencement of welding of structural steel works. a) Welding procedure specification (WPS) b) Welding procedure qualification Record (PAR) ©) Welder Qualification Test (WOT). 2.5.1.11.1 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 D 1.1 Unless otherwise specified, the tolerance for welding groove dimensions shall be as follows: (a) Groove Angle: +/- 5 Deg / AWS D 1.1 - Section 3 - Figure 3.383.4/ and QCS (b) Root Gap: Subject to welding procedure specification / AWS D 1.1 - Section 3 - Figure 3.383.4 11.2 Fit-up Assembly ‘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 used for secure alignment. Generally, the tack welds shall be subject to the same quality requirement as the final welds unless otherwise specifiedNDIA | New Doha International Airport Project PFesixconstruct | METHOD STATEMENT FOR | ren] STRUCTURAL STEEL FABRICATION oa AND PAINTING amine || clone Issue date: 25.09.2010 Document No.- 25045-A1100-51-3GS-S-02.0002 | Rev.0 | Page 15 of 74 1 ‘Tack welds containing any cracks shall be removed thoroughly and replaced with sound tack welds. Size and location of tack welds based on Specification, Where butt welds (Splices) are made between members having different thickness, a transition using a taper of 1: 2.5, on the thicker member shall be provided. This taper may be wholly or partially within the width of the weld. Fit-up Assembly 2.5.1.11.3 Backing Strip Inspection Back-stripped surfaces shall be visually checked for root gap prior to start welding. 2.5.1.11.4 Welding Process The following practices shall be used for welding, ‘*Run-on and run-off plates shall be welded at the ends of weld lines of crucial butt welds. «Prior to welding the surface to be welded and filler material to be used shall be checked.NDIA New Doha International Airport Project " METHOD STATEMENT FOR ne STRUCTURAL STEEL FABRICATION midmac i ios G ‘AND PAINTING Issue date: ‘Document No. 25.09.2010 25045-A1100-51-3GS-S-02.0002 Rev. 0 Page 16 of 74 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 the most appropriate welding condition (current & voltage) shall be maintained with ammeter and voltmeter through out welding work. Alll welding is to be carried out in an approved environment and, if necessary, additional protection may be required. All joints are to be dried before welding in damp climatic condition. During welding work, the most appropriate arc length, angle and welding speed shall be maintained so that welding defects shall be avoided and are energy requirements are satisfied. Fillet weld terminating at the end of members shall be returned continuously around the comer for a distance of 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. All welding shall be carried out in good atmospheric conditions, which permit satisfactory welding and adequate inspection. Whenever possible, welds shall be in fabrication shops. Outdoor welding shall be protected from the effects of adverse weather by the use of temporary shelters. Welders shall mark their ID number beside the length of the weld they have made by permanent paint marker. Weld caps may be dressed to remove minor surface defects by grinding. Where a weld on weld situation occurs, intersecting steel members, the weld reinforcement shall be ground flush with the adjacent plate surface.NDIA New Doha International Airport Project Six METHOD STATEMENT FOR ores STRUCTURAL STEEL FABRICATION midmac \') lors GiJ ‘AND PAINTING Document Ne Issue date 25.09.2010 25045-A1100-51-3GS-S-02.0002 Rev. 0 Page 17 of 74 2.5.1.11.4.1 Type of Welding Process All Welding activities shall be carried out as per the approved Welding procedure specification (WPS). The following Welding Process used in Fabrication works * SMAW Process + FCAW Process (Gas Shielding) SAW Process 2.5.1.11.4.2 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, low hydrogen electrodes (E 7018) shall be used for SMAW welding process. 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 to two hour and later on cooled in the same oven to 100°C. From 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. (Shall be followed AWS D1.1-Table 5.1) Where coated electrodes are used they shall meet the requirements of AWS A 5.1 Grade E-70, Bare Electrode and Granular flux conform to AWS A 5.17, F70.NDIA New Doha International Airport Project | _ METHOD STATEMENT FOR Praxconmme: STRUCTURAL STEEL FABRICATION midmac Ni eben ae AND PAINTING ‘Document No. issu pr 25045-A1100-51-3GS-S-02.0002 Rev.0 | Page 18 of 74 2.5.1.11.4.3 Preheat and Inter- Filler metal for Arches and Skylight framing members, arch support columns and moment frame beam to column connections and all brace frame connection including gusset plate, continuity connections shall have a notch toughness not less than 55 N-m at 21°c as measured by standard charpy V- notch test, ASTM E23. The following Welding consumables used in Fabrication works Welding Process Electrode Specification ‘SMAW. | £7018 FCAW (Gas Shielding) | € 71-1 ‘SAW Flux / Wire - F7A4/EM12K ass Temperature Preheating shall be applied as per AWS D1.1 Table 3.2 -above 65 degree C shall be applied for over 38mm thick of SA 572 Gr 50, S355JR, JO, J2 and K2 steel plate and above 65mm thick material 110 degree C 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. 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. 2.5.1.11.4.4 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. * Ino 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.‘SixConstruct METHOD STATEMENT FOR bala STRUCTURAL STEEL FABRICATION ips ce AND PAINTING mines | close | + Document N =e 25045-A1100-51-3GS-5-02.0002 Rev.0 | Page 19 of 74 + 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, 2.8.1.11.4.5 Visual Examination of Welds Each reinforcement height for butt welds and leg dimensions for fillet welds shall be checked in addition to bead contour appearance. Also, possible presence of such service defects. Viz. 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 & PS -05121805120 ‘Temporary lugs, braces and clips shall be welded in connection with WPS and these shall be removed without damaging the base metal and the area ground flash and smooth. 2.8.1.12 TYPICAL METHODOLOGY FOR FABRICATION AND ASSEMBLY 2.8.1.12.1 TYPICAL METHODOLOGY FOR APM COLUMN FABRICATION AND ASSEMBLY 2.5A.42.4.1 Prep ion of Materi Marking of steel shall be done in accordance with the shop drawings and cutting plan. Material cutting shall be carried out by gas cutting, Either by pug cutting or CNC machine to cut the plates to the required sizes and part ID punch or write by marker on the comments. 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. Joint surfaces shall be free from fins and tears,"NDIA New Doha International Airport Project ce METHOD STATEMENT FOR -2 z STRUCTURAL STEEL FABRICATION midmac |', clloao GiJ AND PAINTING Document No Issue dato 25.09.2010 25045-A1100-51-3GS-S-02.0002 Rev. 0 Page 20 of 74 Preparation of APM Column top segment (Step 1 to 3) Top pate of APM Column with stiffener shall be fixed and weld as per drawing with approved WPS. (Step-1) The bend / covered plate (bottom plate of segment) shall be fixed and weld on the stiffeners as per drawing. (Step-2) The Inspection and testing shall be carried out as per ITP before fix the side plates. Side plates shall be fixed and weld to both side of segment as per drawing and top segment ready for assembly. (Step-3) 2.5.1.12.1.2 Assembly of APM Column comments (step 4 to 6) Proper work platforms shall be prepared for the assembly of APM Column comments. Lay out of the APM Column shall be marked on the platform and temporary fixture brackets to be welded in order to position the permanent structure. Loose components shall be fabricated as per the drawing prior to the assembly works. ‘Shear studs shall be weld and tested as per drawing and ITP on loose components prior to the assembly, Prior to assembly the center line of the column will be marked and fixed, which will be treated as working point during fabrication and even after fabrication. Pre fabricated top segment and vertical plates shall be placed on the lay out using cranes and clamp it firmly without allowing any movement during fixing and welding of all the components. (Step-4) After fixing the vertical plates (4nos) with top segment the base plate shall be fixed as per drawing. Assembly dimension shall be check as per drawing and release for vertical plates welding with top segment and base plate. Qualified welders shall perform welding with approved welding procedures and specified welding materials in accordance with contract requirements. Parts to be welded shall be preheated by means of gas flames; induction heating or other means to bring to the specified preheat temperature. The specified preheat temperature and inter-pass temperature shall be maintained during welding progress.NDIA New Doha International Airport Project 'SixConstruct METHOD STATEMENT FOR + STRUCTURAL STEEL FABRICATION ta GIJ AND PAINTING aides | shoo De it No. : Issue date, 25048-A1100-51-36S-5-02.0002 Rev.0 | Page 21 of74 Welding shall not be done when surfaces are wet or exposed to rain or high winds or when welders are exposed to inclement conditions, The size and lengths of welds shall not be less than those specified in the shop drawing or detail drawings. After completion of vertical plates welding, inspection and testing as per ITP, the one side cover plate shall be fixing and weld as per drawing. (Step-5) Other side of cover plate shall be fixed after re-bars installation by the civil contractor. (Step-6) Once all welding and testing / inspection are completed as per contract specification and ITP, it will be released for painting. Fabrication sequence of APM Column: Step -1 Step-2NDIA New Doha International Airport Project 'SixConstruct METHOD STATEMENT FOR - STRUCTURAL STEEL FABRICATION +3 8 AND PAINTING ameiros || cLoag De ant N¢ eae) 25048-A1100-51-3G8.§-02.0002 Rev. | Page 22 of 74 Step-3 Step-4 Step-5NDIA New Doha International Airport Project SF rsixconstruct METHOD STATEMENT FOR STRUCTURAL STEEL FABRICATION | ioc | wlloao ae AND PAINTING aoe || Ss EVERSENDAI — 25048-Att00-51-305°5-02.0002 Rev.0 | Page 23 of 74 25.09.2010 Step-6NDIA New Doha International Airport Project 'SixConstruct METHOD STATEMENT FOR Piacos STRUCTURAL STEEL FABRICATION 1s ie AND PAINTING amma: | sleae De it NC ont 25045-A1100-51-3G8-5-02,0002 Rev.0 | Page 24 of 74 2.5.1.12.2 TYPICAL METHODOLOGY FOR APM TRACK FABRICATION AND ASSEMBLY 2.5.1.12.2.1 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 cutting, 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. 2.5.1.12.2.2 Assembly of APM Track comments Proper work platforms shall be prepared for the assembly of APM Track comments, Temporary fixture brackets shall be welded on the working platform in order to position the permanent structure. Loose components shall be fabricated as per the drawing prior to the assembly works. Shear studs shall be weld and tested as per drawing and ITP on loose components prior to the assembly or after assembly. Built up sections (Part A, B&C) for the track members shall be fabricated according to the lengths given in the shop drawings as per the Built up fabrication procedure given in section 2.5.1.13, Prior to assembly the center line of the track / beam will be marked and fixed, which will be treated as working point during fabrication and even after fabrication, Pre fabricated Built up Beams (part A) shall be placed on the working platform using cranes and clamp it firmly without allowing any movement during fixing and welding of all the components. (Step-1) The splice of built up beam (part-A) shall be fit-up and weld as per drawing and inspection shall be carried out as per ITP.NDIA New Doha International Airport Project PF sixconstruct METHOD STATEMENT FOR clu STRUCTURAL STEEL FABRICATION Issue date: 25.09.2010 ' midmac AND PAINTING i Document No.: '26045-A1100-51-3GS-S-02.0002 Rev.0 | Page 25 of 74 Pre fabricated Built up T-sections (Part B&C) shall be fix to the above built up beam (part A) as per drawing and arrest with temporary fixtures to prevent any movement during fixing and welding of all the components. (Step-283) Assembly dimension shall be check as per drawing and release for T-Sections welding with main beam After completion of T-Section welding the remaining stiffeners and floor beam connection shall be fixed as per drawing.(Step-4&5) Qualified welders shall perform welding with approved welding procedures and specified welding materials in accordance with contract requirements. Parts to be welded shall be preheated by means of gas flames; induction heating or other means to bring to the specified preheat temperature. The specified preheat temperature and inter-pass temperature shall be maintained during welding progress. Once all welding and testing / inspection are completed as per contract specification and ITP, it will be released for painting Fabrication sequence of APM Track Step -1 (Part-A)NDIA New Doha International Airport Project PF esixconstruct METHOD STATEMENT FOR STRUCTURAL STEEL FABRICATION ey ag AND PAINTING meas | 1 chon Document No. Lape 26045-A1100-51-3GS-S-02.0002 Rev.0 | Page 26 of 74 25.09.2010 Step -2 (Part-A with Part B) Step -3 (Part-A with Part B&C)NDIA New Doha International Airport Project 'SixConstruct METHOD STATEMENT FOR = STRUCTURAL STEEL FABRICATION 189 AND PAINTING mires | ehoae Ieoue date, 25045-41100.51-368-8-02.0002 ev. | Page 27 0t74 Step -4 Step -5NDIA METHOD STATEMENT FOR GiJ AND PAINTING Issue date: Document No. 25.09.2010 2.8.1.12.3 TYPICAL METHODOLOGY FOR Y-COLUMN FABRICATION AND ASSEMBLY 2.5.1.12.3.1 Preparation of Matt New Doha International Airport Project PFrsixconstruct STRUCTURAL STEEL FABRICATION midmac ' vlloas 25045-A1100-51-3GS-S-02.0002 Rev.0 | Page 28 of 74 Marking of steel shall be done in accordance with the shop drawings and cutting plan. Material cutting shall be carried out by gas cutting. 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. 2.8.1.12.3.2 Assembly of Y-Column comments Proper work platforms shall be prepared for the assembly of Y-Column comments. Lay out of the Y-Column shall be marked on the platform and temporary fixture brackets to be welded in order to position the permanent structure. Loose components shall be fabricated as per the drawing prior to the assembly works. Prior to assembly the center line of the column will be marked and fixed, which will be treated as working point during fabrication and even after fabrication. Pre fabricated one side plate shall be placed on the lay out and fix the other side plates (2nos) as per drawing by using cranes and arrest with temporary fixtures to prevent any movement during fixing and welding of all the components (step-2) Inside column stiffeners shall be fixing and weld as per drawing and inspection and testing shall be carried out as per ITP before closing top side plates. After completion of stiffener plates as per above, the top cover shall be fixed as per drawing, (Step-2) ‘Assembly dimension shall be check as per drawing and release for Y-Column covers plates welding. Qualified welders shall perform welding with approved welding procedures and specified welding materials in accordance with contract requirements,|___New Doha International Airport Project _| METHOD STATEMENT FOR oe ean STRUCTURAL STEEL FABRICATION midmac \ ulloas AND PAINTING Issue date: 25.09.2010 Document No: 25045-A1100-51-3GS-S-02.0002 Rev.0 | Page 29 of 74 Fabrication sequence of Y-Column Bottom segment -Step -1 (Materi Parts to be welded shall be preheated by means of gas flames; induction heating or other means to bring to the specified preheat temperature. The specified preheat temperature and inter-pass temperature shall be maintained during welding progress. After completion of welding, base plates and bug girder stub shall be fixed and weld as per drawing (Step-3) Once all welding and testing / inspection are completed as per contract specification and ITP, it will be released for painting. Note: The above similar methodology used for Y-Column top segment fabrication and assembled with bottom segment. The splice shall be welded at site after erection. (Step- 5to7) preparation)NDIA New Doha International Airport Project @#Fsixconstruct METHOD STATEMENT FOR STRUCTURAL STEEL FABRICATION tala: 8 AND PAINTING midmec \', clog jeg Ga Document No. 25.09.2010 25045-A1100-51-3GS-S-02.0002 Rev.o | Page 300f 74 Y-Column Step -2 &3 Y-Column Step -4NDIA New Doha International Airport Project @PFsixconstruct METHOD STATEMENT FOR | STRUCTURAL STEEL FABRICATION os GlJ AND PAINTING mires | sloae Document No: bee 25045-A1100-51-3GS-S-02.0002 Rev.0 | Page 31 of 74 Fabrication sequence of Y-Column Top segment -Step ~ 5&6 —_— Y-Column Bottom and Top segment assembly step -7NDIA New Doha International Airport Project eect METHOD STATEMENT FOR eae STRUCTURAL STEEL FABRICATION iy GlJ AND PAINTING amdiros | clone Document N¢ ber 25045-A1100-51-3GS-S-02.0002 Rev.0 | Page 32 of 74 2.5.1.12.4 TYPICAL METHODOLOGY FOR CAGE COLUMN FABRICATION AND ASSEMBLY 2.8.1.12.4.1 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 cutting. Either by pug cutting or CNC machine to cut the plates and section 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. 2.8.1.12.4.2 Assembly of Cage Column comments Proper work platforms shall be prepared for the assembly of Cage Column comments Temporary fixture brackets shall be welded on the working platform in order to position the permanent structure. Loose components shall be fabricated as per the drawing prior to the assembly works. Beam Built up sections for the Cage Column shall be fabricated according to the lengths given in the production drawings as per the Built up fabrication procedure given in section 2.5.1.13.(step-1) The splice of built up beams shall be fit-up and weld as per drawing and inspection shall be carried out as per ITP. Prior to assembly the center line of the Column / beam will be marked and fixed, which will be treated as working point during fabrication and even after fabrication. Pre fabricated Built up Main Beams 2Nos shall be placed on the working platform using cranes and arrest with temporary fixtures to prevent any movement during fixing and welding of all the components. (Step-2)NDIA New Doha International Airport Project ‘at METHOD STATEMENT FOR Senne STRUCTURAL STEEL FABRICATION ' ie ‘AND PAINTING mires | choo Document No.: Ioue date 25045-a1100.51-905 8.020002 Revd | Page stot After main beams positioning on the fixture, all horizontal and vertical intermediate beams shall be placed in position and each element will be clearly checked for its position and orientation as per the assembly drawing. (Step-2&3) ‘After fixing the all interconnecting beams (horizontal and vertical position), top main beams (2nos) shall be fixed as per drawing (Step-4) Check the assembly dimension as per drawing and fix the top inter connecting beams between top main beams. ‘Assembly dimension shalll be check as per drawing and release for cage column welding Qualified welders shall perform welding with approved welding procedures and specified welding materials in accordance with contract requirements. Parts to be welded shall be preheated by means of gas flames; induction heating or other means to bring to the specified preheat temperature. The specified preheat temperature and inter-pass temperature shall be maintained during welding progress. After completion of welding the cage column top connection beam, plates and bottom base plate shall be fixed as per drawing. (Step -586) Once all welding and testing / inspection are completed as per contract specification and ITP, it wll be released for painting. Fabrication sequence of Cage Column -Step -1 (Material preparation)NDIA New Doha International Airport Project SF sixconstruct METHOD STATEMENT FOR STRUCTURAL STEEL FABRICATION midmac || GiJ AND PAINTING Document No.: Issue date: 25.09.2010 25045-A1100-51-3GS-S-02.0002 Rev. 0 Page 34 of 74 Step -2 Step -3 Step -4 Step -5NDIA New Doha International Airport Project 0 METHOD STATEMENT FOR Fon STRUCTURAL STEEL FABRICATION ' i) AND PAINTING MOO 1S Document No. es Issue date: 25.09.2010 25045-A1100-51-3GS-S-02.0002 Rev.0 | Page 35 of 74 Step 6NDIA ] New Doha International Airport Project METHOD STATEMENT FOR Seco =I, STRUCTURAL STEEL FABRICATION midmac Ky tlload ae AND PAINTING Document No= Teoue dots z eoaa016 25045-A1100-51-3GS-S-02,0002 Rev.0 | Page 36 of 74 2.5.1.12.5 TYPICAL METHODOLOGY FOR ROOF TRUSSES FABRICATION AND ASSEMBLY 2.5.1.12.5.1 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 cutting. Either by pug cutting or CNC machine to cut the plates and section 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. Joint surfaces shall be free from fins and tears. 2.5.1.12,5.2 Assembly of Cage Column comments Proper work platforms shall be prepared for the assembly of truss segments. Lay out of the truss shall be marked on the platform and temporary fixture brackets to be welded in order to position the permanent structure. Loose components shall be fabricated as per the drawing prior to the assembly works. If any built up sections for the trusses members shall be fabricated according to the lengths given in the shop drawings as per the Built up fabrication procedure given in section 2.5.1.13 Prior to assembly the center line of the beam will be marked and fixed, which will be treated as working point during fabrication and even after fabrication. Pre fabricated chord members shall be placed on the fixture using cranes and arrest with temporary fixtures to prevent any movement during fixing and welding of all the components. (Step-1) After main chord positioning on the fixture, all intermediate beams / Pipes shall be placed in position and each element will be clearly checked for its position and orientation as per the assembly drawing.(Step -2&3) ‘Once confirmations of all beams / Pipes in assemble as per drawing, following things will be carried out.NDIA New Doha International Airport Project METHOD STATEMENT FOR bias STRUCTURAL STEEL FABRICATION Te df AND PAINTING ares |) clas Document No= lesue dae, 25045-A1100-81-368.$-02.0002 Rev.0 | Page37of74 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, clamp and wedges where practicable + Any wedges used to space root gaps shall be removed from the root gaps immediately after tacking and before making the root run. ‘+ Longitudinal seam welds of lengths of plates shall whenever possible, be evenly staggered, but in any case by at least 100 mm. + After completion of joint fit-up, Eversendai QC Inspector will check the fit-up and assembly dimension as per drawings / spectfication and he will release the joint for welding. Qualified welders shall perform welding or welding operators using approved welding procedures and specified welding materials in accordance with contract requirements. Parts to be welded shall be preheated by means of gas flames; induction heating or other means to bring to the specified preheat temperature. The specified preheat temperature shall be maintained as a minimum inter-pass temperature as welding progress. The size and lengths of welds shall not be less than those specified in the shop drawing or detail drawings. Each end of a long member will have match mark on top of member for easy identification. ‘Always match mark “A’ will be at lower end of each assembly and assembly. at the top end Once all welding and testing / inspection is completed as per contract specification and procedures, it will be released for painting.NDIA New Doha International Airport Project METHOD STATEMENT FOR ee STRUCTURAL STEEL FABRICATION ' a AND PAINTING memes ¢ Document No ee Issue date: 25.08.2010 25045-A1100-51-3GS-S-02.0002 Rev.0 | Page 38 of 74 Fabrication sequence of Roof Truss -Step -1 -Main chord ‘Step -2— Inter connecting members Step -3 - Inter connecting members A AAANDIA New Doha International Airport Project #Fsixconstruct METHOD STATEMENT FOR STRUCTURAL STEEL FABRICATION 1 ae AND PAINTING cE 1 Document No. Issue date: 25.09.2010 25045-A1100-51-3GS-S-02,0002 Rev.0 | Page 39 of 74 2.5.1.12.6.2 Typical Truss Assembly & Typical working platform TORS DORON SST WITNDIA T |____New Doha International Airport Project | . METHOD STATEMENT FOR | Secon PAI] | STRUCTURAL STEEL FABRICATION ‘ AND PAINTING meiner | eka Issue date: 25.09.2010 Document No 25045-A1100-51-3GS-S-02.0002 Rev.0 | Page 40 of 74 2.5.1.12.6 2.8. 25. TYPICAL METHODOLOGY FOR COLUMN, BEAMS & MISC STRACTUR FABRICATION AND ASSEMBLY 1.12.6. 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 cutting. Either by pug cutting or CNC machine to cut the plates and section 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. All connection plates shall be prepared as per drawing requirement Joint surfaces shall be free from fins and tears. .1.12.6.2 Assembly of Connection Plates with Column / Beams. Proper work platforms shall be prepared for the fixing the connection plates with column or Beam as per drawing requirement. Loose components (connection plates) shall be fabricated as per the drawing prior to the Column /Beam fabrication. The center line of the column / beam will be marked and fixed, which will be treated as working point during fabrication. Pre fabricated connection plates / stub &etc shall be fixed on the column / beams as per drawing After completion of the connection plates / stubs fixing on column and beam and each connection plates will be clearly checked for its position and orientation as per the drawing After completion of connection plate’s joint ft-up, Eversendai QC Inspector will check the fit-up, orientation and dimension as per drawings / specification and he will release the joint for welding. Qualified welders shall perform welding or welding operators using approved welding procedures and specified welding materials in accordance with contract requirements.NDIA New Doha International Airport Project Six Construct METHOD STATEMENT FOR + STRUCTURAL STEEL FABRICATION 3 i AND PAINTING quires (1 clas Docur it Ne eau date: 26045-A1100-51-368-5-02.0002 Revo | Paget of 4 Parts to be welded shall be preheated by means of gas flames; induction heating or other means to bring to the specified preheat temperature. The specified preheat temperature shall be maintained as a minimum inter-pass temperature as welding progress. Welding shall not be done when surfaces are wet or exposed to rain or high winds or when welders are exposed to inclement conditions. The size and lengths of welds shall not be less than those specified in the shop drawing or detail drawings. Each end of a column / beam will have match mark on flange for easy identification. Once all welding and testing / inspection is completed as per contract specification and procedures, it will be released for paintingNDIA New Doha International Airport Project areca METHOD STATEMENT FOR + STRUCTURAL STEEL FABRICATION 15 6a wy AND PAINTING ed De it Ne Co 25045-A1100-51-2G8-5-02.0002 Rev.0 | Page 42 of74 2.5.1.12.6.3 Typical Fabrication & Lay out Sd 3 Truss Assembly 3 ‘Arch Assembly aryNDIA New Doha International Airport Project @#Frsixconstruct ; METHOD STATEMENT FOR STRUCTURAL STEEL FABRICATION Na og AND PAINTING mad, || chasse Issue date 25045-A1v00-51 308-8-02.0002 rev.o | Pages ot74 25.09.2010 ‘Typical Arch Column Assembly ylNDIA New Doha International Airport Project METHOD STATEMENT FOR STRUCTURAL STEEL FABRICATION AND PAINTING Issue date: 25.09.2010 Document No. 25045-A1100-81-3GS-S-02,0002 Rev.0 | Page 44 of 74 2.5.1.13 PROCEDURE FOR BUILT UP GIRDERS / BEAMS 2.5.1.13.1 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,NDIA New Doha International Airport Project Misdiaaial METHOD STATEMENT FOR bal STRUCTURAL STEEL FABRICATION Les GlJ AND PAINTING mines (1 clase Document N Se eeaaw 25045-A1100-51-36S-S-02.0002 Rev.0 | Page 45 of 74 2.5.1.13.2 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, Eversendai QC Inspector shall be check the fit-up and release for welding 2.5.1.13.3 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 65°c by means of gas fiame 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) The 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.Il NDIA New Doha International Airport Project METHOD STATEMENT FOR cea PAPA] STRUCTURAL STEEL FABRICATION | ins | cloao AND PAINTING Issue date: 25.09.2010 Document No. oa 25045-A1100-51-3GS-S-02.0002 Rev. 0 | Page 46 of 74 Built up Girder Welding 2.5.1.4 NON-DESTRUCTIVE TESTING (NDT): All non-destructive testing shall be performed as per approved agency as per the contract in accordance with the requirements of the applicable standards and project specifications. Personnel for NDT shall be qualified in accordance with ASNT recommended practice SNT-TC-1A. Non-destructive Testing shall be performed as follows: Visual NDT TYPE SINo. Description inspection i MPT © UT on CP Welds UT on 38mm and above thicker plate subject o % 1 through thickness welds score, 100% ~ shrinkage strain. + MPT on Fillet Welds +) Wieb-Flange connection |. MPT on CP Welds (below 1%) 0% Beam and ‘8mm thick) & PPW (Partial | fey coresaen tena 2 Penetration Welds) - All 100 inde athewice 1008 Thickness + Allthos connactons - ‘00% A third party Inspection agency shall be engaged as independent and approved testing and inspection agency to carry out the UT and MPT on Weldments.NDIA New Doha International Airport Project SixCo : METHOD STATEMENT FOR ene Glu STRUCTURAL STEEL FABRICATION midmac ii ulloas AND PAINTING Issue date: 25.09.2010 Document No. 25045-A1100-1-3GS-S-02.0002 Rev.0 | Page 47 of 74 2.8.1.14.1 General requirement of visual Inspection Weld Visual inspection shall be carried by QA/QC Engineers or Experience welders / foreman or certified Welding Inspector as per AWS D 1.1 / QCS 2007 for external defects like, surface porosity, under cut, excess penetration, over laps, lack of penetration or incomplete fusion and fillet sizes. Weld visual inspection report shall be maintained (EVS/FR/010/01) for each drawing. 2.5.1.14.2 General requirements of liquid penetrant testing (PT) Liquid Penetrant Testing procedures shall be in accordance with ASTM E 165.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 Appendix B. 2.5.1.14.3 General requirements of Magnetic Particle Testing (MT) Magnetic particle Testing procedures shall be in accordance with ASTM E 709 or AWS p44 The evaluation of indications and the acceptance criteria shall be in accordance with ASTM E 709 or AWS D 1.1 Independent testing authority MPI reports shall be obtained for filet welds. 2.5.1.14.4 General requirements of Ultrasonic Examination (UT): ‘The ultrasonic Testing of plates for lamination shall be in accordance with SA 435 and of Butt joint shall be in accordance with ASTM E 164 or AWS D 1.1 Independent testing authority UT reports shall be obtained for all butt joints. 15 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 in required tolerance the member shall be corrected prior to further process. Al dimensions shall be recorded in approved format. 100% visual inspection shall be carried out for external defects.NDIA ] New Doha International Airport Project 'SixConst METHOD STATEMENT FOR + clu STRUCTURAL STEEL FABRICATION . AND PAINTING andres | clean Issue date: 25.09.2010 Document No. 25045-A1100-51-3GS-S-02.0002 Rev.0 | Page 48 of 74 Eversendai QA/JQC Engineer shall conduct the final Inspection and review all inspection reports and prepared as per Inspection and test plan (ITP) 2.5.1.16 GENERAL TOLERANCES The following standards / specifications shall be used: ASTM A6 / BS EN 10025-2/ BS 5950-Part1 — Specification for general requirements for rolled steel plates, shapes, Sheet piling, and bars for structural use. Architecturally exposed structural steel tolerance as accordance with project specification -05121 & 05120 AWS D 1.1 - 2008 / AISC- Specification for structural steel Contract Specification -05120 / 05121/05060 2.5.2 TEMPORARY WORK All temporary and non-structural attachments like cleats shall be removed either by Gas cutting or by grinding, If thermal cutting is employed, the attachments shall be cut off at a minimum distance of 3 mm from the surface of the material and then ground flush. During grinding, care must be taken not to over-grind into the base metal by more than 0.25 mm depth. After grinding, 100% dye penetrant test shall be carried out on the area of the attachment weld. In case the ground area falls below the allowable limits or as per client specifications on minimum base metal thickness requirements, the area shall be repaired by welding, in accordance with approved welding procedures.