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INSPECTION Gr

FIELD INSPECTION REPORT ffi:-'-"


INSPECTION TYPE WORK No.
STEEL STRUCTURE INSTALLATION INSPECTION ITEM No
AREA / LOCATION
ITEIM No. DESCRIPTION SIGNATURE
INSPECTION NOTICE No OWNER CONSORTIUM CONTRACTOR
OWNER'S INSPECTOR
CONSORTI UM'S INSPECTOR
CONTRACTOR'S INSPECTOR
REFERENCE Drawing. No
I'IGHTENING METHOD

I Calibrated Wrench Method Twist-of-Type Tensron Control

INSPECTION ffiTACC-T--REJ
1 LOCATION
2. VERTICALITY
3. HEIGHT
4 HORIZONTALITY
5. FOUNDATION AND ANCHOR BOLT
6. SHIMMING
7 WELDING
B, BOLT I"ORQUI NG/I'IG HTEN'NG
9. GIlOUTING
1O PAINTING (TOUCH-UP)

OTHERS
1 TORQUE WRENCH CALIBRATION
2 CRANE / HOIST RAIL INSTALLATION

COMMENTS

LEGEND ACC ACCEPI- N.A. Not Apptjcabte REJ REJECT

fjoRfi/ No. c-40


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INSPECTION Gr. :

REPORT NO. :

FIELD INSPECTION REPORT


INSPECTION TYPE:
STEEL STRUCTURE ALIGNMENT INSPECTION ITEM No. :

AREA / LOCATION
ITEM No. DESCRIPTION: SIGNATURE
INSPECTION NOTICE No CONTRACTOR
OWNER S INSPECTOR
CO lr SOniTVLY r'f .S P rCrO n
CONTRACTOR'S I NSPECTOR
REFERENCE Drawing. No

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COLUMN VERTICALITY TOP OF BEAM LEVEL

LEGEND ACC ACCEPT N.A. : NotApplicable REJ: ttEJECT

FORM NO C.41
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FIELD INSPECTION REPORT ffi;:-,-"


INSPECTION TYPE: WORK No.
STEEL STRUCTURE ACCESSORIES INSPECTION
AREA / LOCATION :

ITEM No DESCRIPTION SIGNATURE


INSPECTION NOTICE No OWNER CONSORTIUM CONTRACTOR
OWNER'S INSPECTOR
CONSORTI UM'S INSPECTOR
CONTRACTOR'S I NSPECTOR
REFERENCE Drawing. No.

o
6 o o
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0'= 6 c
c
-6
C
VISUAL INSPECTION so .o o .c REMARKS
Io N o e
qa o 0_
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ACCESSORIES
'l . Platform
2. Ladder
3. Grating
4. Checker Plate
5. Handrail
6. Stair
7

10

COMMENTS

LEGEND ACC: ACCEPT N.A. NotAppllcable REJ: REJECT

FORM NO. C-042


METHOD OF STATEMENT FOR STEEL
Document Description
STRUCTURE & ERECTION
The Egyptian Ethylene and Derivatives Company
Client
(ETHYDCO)
On Shore JV TOYO and ENPPI
Document No. PJ-EEP2-ST.S-PRO-0001 Rev. Sheet
Job Location Ameriya Alexandria, Egypt 2 2 of 13

TABLE OF CONTENTS

1.0 SCOPE ................................................................................................................ 3


2.0 REFERENCE DOCUMENTS .............................................................................. 3
2.1 ABBREVIATIONS ........................................................................................... 3
2.2 CODES ........................................................................................................ 3
2.3 CONTRACTOR'S DOCUMENTS ....................................................................... 4
2.4 ASSOCIATED PETROJET PROCEDURES ......................................................... 4
3.0 RESPONSIBILITY .............................................................................................. 4
3.1 CONSTRUCTION MANAGER ........................................................................... 4
3.2 QA/QC MANAGER........................................................................................ 4
4.0 MATERIAL AND EQUIPMENT........................................................................... 4
4.1 STEEL STRUCTURES ................................................................................... 5
4.2 W ELDING FILLER METAL .............................................................................. 5
4.3 EQUIPMENT AND TOOLS .............................................................................. 5
5.0 PLANNING OF ACTIVITIES AND MONITORING OF PROGRESS ................. 5
6.0 ERECTION DRAWINGS .................................................................................... 5
7.0 RECEIVING, HANDLING AND STORING MATERIAL ..................................... 6
8.0 CHECK FOR FOUNDATIONS........................................................................... 6
9.0 PRELIMINARY CHECKS .................................................................................. 6
10.0 MATERIAL WITHDRAWAL............................................................................... 7
11.0 ERECTION .......................................................................................................... 7
11.1 GENERAL ..................................................................................................... 7
11.2 MOUNTING GUIDELINES ................................................................................ 8
11.3 INTERMEDIATE INSPECTION ..........................................................................10
11.4 FINAL INSPECTION ....................................................................................... 10
11.5 TOLERANCES .............................................................................................. 10
11.6 REPAIR OF GALVANIZED STEEL.................................................................... 10
12.0 TESTING AND INSPECTION ............................................................................. 11
13.0 GROUTING ........................................................................................................ 12
14.0 QUALITY RECORDS......................................................................................... 12
15.0 APPENDIX ......................................................................................................... 12
METHOD OF STATEMENT FOR STEEL
Document Description
STRUCTURE & ERECTION
The Egyptian Ethylene and Derivatives Company
Client
(ETHYDCO)
On Shore JV TOYO and ENPPI
Document No. PJ-EEP2-ST.ST-PRO-0001 Rev. Sheet
Job Location Ameriya Alexandria, Egypt 2 3 of 13

1.0 SCOPE

This procedure describe the minimum requirements that shall be observed at site for handling and
storing materials, erection of hot dip galvanized primary and secondary steel structure to be installed .
It also covers the tests and inspections that are to be carried out during the execution of the
assembly works.
And this procedure covers Steel Structures, Steel from Building, Supporting Steel, Steel Pipe Rack,
and Miscellaneous Structure Steel.
The objective is to ensure that all the activities are carried out:
In accordance with approved procedures, specifications and drawings,
Using special working and control process which have been previously qualified;
employing qualified and, when required, certified personnel;
using material which are kept under control from receiving throughout entire
working cycle;
Performing all tests, measurements and inspection required by Contract.

2.0 REFERENCE DOCUMENTS

2.1 ABBREVIATIONS

ITP = Inspection & Testing Plan


QC = Quality Control

2.2 CODES (BRITISH STANDARDS )


2
AISC (9 th edition) The American Institute of Steel Construction.
AWS D1.1 Structural Steel Welding Code.
(B S) British Standard.
(ISO) International Standard Organization.
ANSI American National Standard Institute.
ASTM American Society for Testing and Materials.
METHOD OF STATEMENT FOR STEEL
Document Description
STRUCTURE & ERECTION
The Egyptian Ethylene and Derivatives Company
Client
(ETHYDCO)
On Shore JV TOYO and ENPPI
Document No. PJ-EEP2-ST.ST-PRO-0001 Rev. Sheet
Job Location Ameriya Alexandria, Egypt 2 4 of 13

2.3 CONTRACTOR'S DOCUMENS

Minimum Quality Requirements for Site Activity.


Steel Structural Works Technical Specification.
Steel Structure Standard Drawings and Details.
ED-9999-STR-SPEC-000-JB611 Specification Of Steel Structure.
2
CD-9999-FQC-PRC-000-001 QC Procedure.
ED-9999-PJM-PEP-000-006[1] Project Quality Plan.
ITP NO: 2001 : 2011 Inspection & Test Plan for Mechanical Works.
ITP NO:20 Structural Steel (Erection).

2.4 ASSOCIATED PETROJET PROCEDUR 2

PJ-EEP2-MRI-PRO-0001 Method of Statement of Material Handling , Storage Procedure


PJ-EEP2-NR-PRO-0001 Non Conformance Management Procedure.
PJ-EEP2-NDT-PRO-0001 Visual Inspection Procedure.
3.0 RESPONSIBILITY

3.1 CONSTRUCTION MANAGER

The Construction Manager is responsible for the implementation of this procedure for
the over all direction and coordination with the QA/QC Manager for monitoring,
coordinating
and control of all the erection activities.

3.2 QA/QC MANAGER

The Site QA/QC Manager is responsible to verify the proper implementation of the quality
systems and to implement quality control activities related to erection.

4.0 MATERIAL AND EQUIPMENT

4.1 STEEL STRUCTURES

The Steel Structures shall mainly consist of the following:


Steel Building and Shelter
Pipe Racks / Steel Structure
Equipment Platform, Stair and Walkways / Handrails/Cross over /Shetters.
Minor Steel Structure / Supports / Ladders / Grouting /Beams, etc.
METHOD OF STATEMENT FOR STEEL
Document Description
STRUCTURE & ERECTION
The Egyptian Ethylene and Derivatives Company
Client
(ETHYDCO)
On Shore JV TOYO and ENPPI
Document No. PJ-EEP2-ST.ST-PRO-0001 Rev. Sheet
Job Location Ameriya Alexandria, Egypt 2 5 of 13

4.2 WELDING FILLER METAL

When required for any modification Welding filler metal shall conform now to BS 5135,
BS 639 and ISO 5182 /E7018 welders and welding WPS as per BS4871 & BS 4872
4.3 EQUIPMENT AND TOOLS

All tools and equipments to be used for erection shall be standard (not allow any
fabricated or hand made fouls) in good order, safe condition and sufficient quantity.
Examples of tools and equipment are:
Cranes
Lifting gear including sling wires,belts,chackles,ect.
Plastic Ropes to be used as guide only during lifiting not for any lift. 2

Standard tools such as spanners,


Transportation Trucks
Torque Wrenches
5.0 PLANNING OF ACTIVITIES AND MONITORING OF PROGRESS

The Project Planner is responsible to plan the sequence of erection of steel structure
according to the Construction Master Schedule.
He is also responsible to monitor the progress of the work and to keep informed the
Construction Manager and Project Manager for any deviation from the original schedule.
Planning of steel structure erection shall be made according to erections priority
and material availability.
6.0 ERECTION DRAWINGS

The Technical Office (TO) receive the steel structures drawings from engineering department.
Based on the availability of drawings, material after fabrication, specifications and in
congruence with planning, TO shall issue detailed drawings for erection and copy to all the
concerned departments (AFC DWGS & Last Rev). 1

The following information shall be provided in the detailed drawings:


Identification of each item, part or assembly number with match mark and other
information as necessary for easy identification and erection;
Specific instruction, as necessary for erection;
METHOD OF STATEMENT FOR STEEL
Document Description
STRUCTURE & ERECTION
The Egyptian Ethylene and Derivatives Company
Client
(ETHYDCO)
On Shore JV TOYO and ENPPI
Document No. PJ-EEP2-ST.ST-PRO-0001 Rev. Sheet
Job Location Ameriya Alexandria, Egypt 2 6 of 13

7.0 RECEIVING, HANDLING AND STORING MATERIAL

The Material Control Manager (MCM) shall receive all steel structures in accordance with the
procedure and shall be responsible for checking quantity and type of materials indicated in
the packing list and QC inspector checks for quality. The damages shall be immediately
notified to take the required measures.
The materials shall be stored, handled and preserved in accordance with the procedure.
8.0 CHECK FOR FOUNDATIONS
Before commencing work, center lines, locations, orientation, chipping and
elevations of foundations shall be checked for prescribed tolerances.
Support shims shall be located after marking the centre lines on the plinths.
At least 3/4 shims packs with levelling mortar shall be provided for the base plates of each
column. Centre lines marked on plinths shall have a tolerance of 1 mm and elevation
of 1 mm.
The foundation bolt surface that will come in contact with concrete shall be free from
dirty and oily matters or points. Foundation surface shall be chipped prior to erection activity.

9.0 PRELIMINARY CHECKS

According to the sequence and schedule of erection, the following preliminary checks
shall be carried out before erection activities begin, in order to verify:

The availability of experienced, qualified personnel and equipment necessary to


carry out the works;
The availability of fabricated steel structure and its status of acceptance.
The status and availability o f approved for Construction drawings and
/or specifications.
All tools and equipments used for erection are calibrated as per Calibration of
Inspection and Testing Equipment procedure
The status of torque wrench calibration the above preliminary checks shall be
jointly made by all the concerned as i n responsibility matrix.
METHOD OF STATEMENT FOR STEEL
Document Description
STRUCTURE & ERECTION
The Egyptian Ethylene and Derivatives Company
Client
(ETHYDCO)
On Shore JV TOYO and ENPPI
Document No. PJ-EEP2-ST.ST-PRO-0001 Rev. Sheet
Job Location Ameriya Alexandria, Egypt 2 7 of 13

10.0 MATERIAL WITHDRAWAL


According to the erection sequence, priority and on basis of the availability of approved for
Construction drawing and material, the fabrication supervisor retrieves the material from
warehouse and handles it in accordance with the procedure And with specific care to avoid
damage to surface preparation.
11.0 ERECTION

11.1 GENERAL

Erection shall be in accordance with Re fer e nce documents listed in item 2.0 and shall include
the setting of all columns, beams, trusses, grating and handrails, the erection and complete
installation of all other structural steel to true line, grade and plumpness.
Structural steel shall be plumbed with suitable guy wires and held in plumb during field erection.
Guy wires shall be placed so as not interfere with other necessary work.
The setting out of the works - the accurate positioning, plumbing, lining, and leveling of all
steel works shall be in accordance with the drawings.
Steel shall not be placed or erected on concrete foundations or floor slabs until the concrete has
cured.c
Holes shall not be made or enlarged by thermal cutting to correct fabrication errors. Minor
rectification to holes as necessary for field installation shall be made by drilling and subsequent
touch up by zinc rich paint such as galvofroid.
All work during erection shall be securely bolted and if required temporarily braced. No permanent
bolting shall be executed until correct position and alignment have been obtained
No equipment shall be supported from the steelworks until the structure is securely bolted, grouted
and inspected.
Every erected steel component shall be free from contamination, twist and distortion.
Correction of minor misfits and a reasonable amount of reaming and cutting shall be considered a
legitimate part of erection. Any error in shop work which prevents the proper assembling and
fitting up to parts by the moderate use of drift pins, reaming or cutting shall be reported
immediately and approval shall be obtained for the method of correction prior to connecting the
error.
METHOD OF STATEMENT FOR STEEL
Document Description
STRUCTURE & ERECTION
The Egyptian Ethylene and Derivatives Company
Client
(ETHYDCO)
On Shore JV TOYO and ENPPI
Document No. PJ-EEP2-ST.ST-PRO-0001 Rev. Sheet
Job Location Ameriya Alexandria, Egypt 2 8 of 13

The contact surfaces of bolted elements shall be free from rust, mill scale, grease, etc. Bolts
already used and previously tightened shall not be re-used.
All site bolted connections shall be assembled and torque tightened in accordance with Appendix
A. After the torque tightening of bolts shall be identified by the paint on the bolt head.
All material, plant and equipment used shall be of sound construction and free from flaws.
Bolts designed for transmitting forces in structural member connections, shall have a minimum
diameter as follows:
Minimum diameter
For main members, bracings and struts 20mm
For secondary, i.e. bracings, purlins, 16mm
Ladders, handrails, etc.
(Unless noted otherwise on standard drawings).
Except otherwise noted on design drawing, hole diameter for bolts shall be as follows
Diameter bolt, plus:

For steel-to steel connections : 2mm


For steel-to-concrete connections (anchor bolts):
o Up to 24 mm bolt diameter : 4mm
o 24 to 32 mm bolt diameter : 6mm
o 32 mm bolt diameter and over : 8mm
The spacing of bolts in the direction in which the force is applied shall be at least three bolt
diameters (measured in the direction of the force).
The minimum distance from center of bolt edge of plate measured in the direction of force shall
be two bolt diameters, and measured at right angles to the direction of force, one and a half bolt
diameters.
Slotted hole connections are to be executed in such away, that these connections may perform
their design function, as indicated on the design drawings, and shall be provided with washers.
High-strength bolts shall be used for structural steel-to-steel connections.
High-strength bolts shall be used for in bearing-type connections and not as friction grip bolts
11.2 MOUNTING GUIDELINES
If required, additional drilling of beams, columns or other components shall be made to
remedy fabrication mismatch / faults. Magnetic base drills shall be used for such work.
METHOD OF STATEMENT FOR STEEL
Document Description
STRUCTURE & ERECTION
The Egyptian Ethylene and Derivatives Company
Client
(ETHYDCO)
On Shore JV TOYO and ENPPI
Document No. PJ-EEP2-ST.ST-PRO-0001 Rev. Sheet
Job Location Ameriya Alexandria, Egypt 2 9 of 13

Based on the defined priority, structural members shall be assembled prior to erection for
ease of construction with due consideration to lifting capability and study.
The following sequence shall be followed:
Clean the foundation pockets and anchor bolts and chipping. 2

Prepare shim plate above concrete mortar and control the required bottom elevation
of steel structure base plate;
Ensure the correct gap between bottom of base plate and top of concrete
For required Grout thickness;
Mounting of first level of columns/beams or assembly;
Splicing and diagonal measurement at various phases /Floors;
Check verticality of columns in two directions and base plate elevation;
Bolt tightening;
Control of splicing (bolted) and diagonal measurement at various phases;
Control of bolting.
Nuts and washers shall be as specified in the drawings.
Tightening of joints shall require first tightening of mid bolts and then of adjacent bolts.
Tightening of big joints shall be carried out in two steps using first a torque of approx. 60%
of the prescribed value and then the prescribed torque.
Grouting of the column base plates can be executed after checking for diagonal
splicing and bolting or after completed operations as specified above.
Nelson nails or equivalent for grating fastening shall be nailed; surfaces where the Nelson
nails will be applied shall be previously cleaned to remove grease, oxides, etc.
Friction joints column to column:
Contact end surfaces of the joints between the column sections shall be flat.
Joint covers and their padding if any shall be mounted after checking
For the contact.
Each joint before tightening shall be checked for holes coaxiality.
Friction joining of the column beam to the butt flange:
End flanges shall be delivered to site already connected at manufacturer shop after
METHOD OF STATEMENT FOR STEEL
Document Description
STRUCTURE & ERECTION
The Egyptian Ethylene and Derivatives Company
Client
(ETHYDCO)
On Shore JV TOYO and ENPPI
Document No. PJ-EEP2-ST.ST-PRO-0001 Rev. Sheet
Job Location Ameriya Alexandria, Egypt 2 10 of 13

Checking at a pre-erection stage for correct distance of the connected column


Flanges to beam.
Handrails and toe plates shall be not welded to the columns; however they shall be
Adequately jointed in the vicinity of the columns.
When not provided in the design drawings, the tube passage through grating shall
be admissible only in case grating is adequately reinforced at the pass hole.
A toe plate shall be provided around the pass hole.
11.3 INTERMEDIATE INSPECTION

Each framework floor shall be checked for verticality and diagonals before and after tightening of
bolts.
Survey instrument shall be used for checking of verticality. When executing the tests, proper
consideration shall be given to the deformation changes occurring in the steel structure during a day
on account of exposure to the sunlight.
Verticality:
1
Verticality and levelness shall be checked by means of a Survey instrument.
For verticality reference shall be made to points (flags) marked on columns;
Diagonals (in plan):
Diagonals shall be checked using a metric roller;
All structural framework / floors shall be checked;

11.4 FINAL INSPECTION

Check for steel structure framework verticality, horizontal alignment and height shall be carried
out after mounting.
Splicing shall be executed in accordance with prescriptions listed para 9.4. Bolt torque
tightening shall be as mentioned in the Appendix Completeness check as per approved for
construction drawings.
After checking of connection, the erecion drawing shall be marked to indicate acceptance.
11.5 TOLERANCES

The deviation in overall dimensions, positions, alignments, plumpness and


elevations shall not exceed the limits specified in specification.
METHOD OF STATEMENT FOR STEEL
Document Description
STRUCTURE & ERECTION
The Egyptian Ethylene and Derivatives Company
Client
(ETHYDCO)
On Shore JV TOYO and ENPPI
Document No. PJ-EEP2-ST.ST-PRO-0001 Rev. Sheet
Job Location Ameriya Alexandria, Egypt 2 11 of 13

11.6 REPAIR OF GALVANIZED STEEL

Any damage to galvanized steel shall be repaired in accordance with ASTM A780.
Before repairing the damaged galvanized coating, the exposed substrate metal shall be cleaned to bright
metal
and free of all visual rust, oil or grease. Any none adhering galvanizing shall be removed to the
extent that the surrounding galvanizing is integral and adherent.
12.0 TESTING AND INSPECTION

Inspection and test shall be carried out by qualified personnel, coordinated by SQM, according to
the Inspection & Testing Plan (ITP).
All structural steel material and fabrication shall be subject to inspection by client
Welds shall be inspected by contractor according to the previsions of regulatory requirements with
respect to technique, equipment, and acceptance criteria and personnel qualifications. All welds
shall be subject to random visual inspection by client .in addition, the following special
requirements shall apply to welding inspection.
Grating shall be tagged with metal plate having raised letters so that the mark shall be seal welded
to the grating prior to galvanizing.
Contractor may submit alternate proposal for marking galvanized members, subject to clients
written approval.
SQM shall manage all Witness and Hold Points shown on the ITP, including convocation to
Contractor.
The form worked out toyo shall be used for issue of the certificates listed in the Inspection and
Test Plan The Inspection mentioned in the Inspection and Test Plan shall be carried out using the
following calibrated instruments:
Optical levels, steel metric rollers, water levels, manual dial type torque wrench for torque read-out.
10% of all connections for each bolt size shall be randomly selected and inspected, of each
joint shall show the tightening value of high strength bolts. Such test shall be conducted on
minimum 2 bolts per each joint.
Tested bolts shall be clearly marked with paint.
Each high strength bolts assembly shall consists of one heavy semi-finished hexagon structure
METHOD OF STATEMENT FOR STEEL
Document Description
STRUCTURE & ERECTION
The Egyptian Ethylene and Derivatives Company
Client
(ETHYDCO)
On Shore JV TOYO and ENPPI
Document No. PJ-EEP2-ST.ST-PRO-0001 Rev. Sheet
Job Location Ameriya Alexandria, Egypt 2 12 of 13

bolts one heavy semi-finished hexagon nuts and one hardened washer to be used the nut
In presence offload indication Washers ,turn-of nut tightening follow-up; one nut sample per each
size of bolts shall be unscrewed by at least 1/6 turn and then to check whether the prescribed torque
brings the nut back to its original position.
Galvanized bolts shall not be reused after unscrewed; bolts may be reused after repaint
by galvanize spray.
13.0 GROUTING
All bearing plates, loose lintels, beams and columns shall be shimmed to proper grade and
level before grouting.
Grout material as specified in the technical specification or on drawing shall be used.
The sand-cements mixture shall be combined with the least amount of water to produce a low
slump, place able grout.
Prior to setting structure, the concrete surface to receive grout shall be chipped to a depth of
6 mm to obtain a roughened surface.
After the structure is a place, positioned and shimmed immediately before grouting, the surface to
receive grout shall be cleaned and wetted. Excess water shall be removed.
Grout shall be placed and thoroughly worked to eliminate voids and provide a uniform bearing
surface under the base plate.
When specified on drawings, epoxy grout shall be used for grouting under heavy equipment
where large bearing and /or vibration stresses occur. Epoxy grout shall be mixed by mechanical
mixer and placed in accordance with manufacturer instruction.
14.0 QUALITY RECORDS

The following records shall be provided:


ITP and Procedure
Certificates of materials supplied
Dimensional reports
Bolt torque tightening reports
Surface treatment reports
Grouting reports
Final dossier containing the report of the test carried out
METHOD OF STATEMENT FOR STEEL
Document Description
STRUCTURE & ERECTION
The Egyptian Ethylene and Derivatives Company
Client
(ETHYDCO)
On Shore JV TOYO and ENPPI
Document No. PJ-EEP2-ST.ST-PRO-0001 Rev. Sheet
Job Location Ameriya Alexandria, Egypt 2 13 of 13

15.0 APPENDIXB
1
1- Torque Tightening of Steel Structure Table 001.
2- Steel structure installation inspection C-40.
3- Steel Structure Alignment Inspection C-41.
4- Steel Structure Accessories Inspection C-42.
TORQE TIGHTENING OF STEEL STRUCTURE

Bolts Classes 8.8 and 10.9

The tightening torque shall be in accordance with the following Table 001.

Nominal Diameter of Bolt in mm Tightening Torque in NM


12 94
14 148
16 234
18 320
20 456
22 616
24 787
27 1150
30 1562
33 2125
36 2729
39 3532

Form No. Table :001