DOCUMENT SUBMITTAL HISTORY

A 2020-01-31 DRO / OIZ PRO RRO First Issue

Prepared Reviewed Approved
Revision Date Description
by by by

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 2 / 162
TABLE OF CONTENTS

1 INTRODUCTION ...............................................................................................................................6

1.1 LOCATION ...............................................................................................................................6

1.2 EXISTING LAYOUT AND SITUATION ....................................................................................6

1.3 NEW LAYOUT AND INTEGRATION IN EXISTING SITUATION............................................. 7

1.4 PROJECT’S SCOPE ................................................................................................................8

2 METHOD STATEMENT´S SCOPE ...................................................................................................9

3 WORKING AREAS..........................................................................................................................10

3.1 TOPOGRAPHICAL SURVEY .................................................................................................11

3.2 LOCATION OF SITE AND SERVICES ..................................................................................11

3.3 WORKERS ACCOMODATION ..............................................................................................14

3.4 PRECAST AND STEEL YARD (CASINGS AND REBAR) .....................................................14

3.4.1. Steel Casings Yard .........................................................................................................15

3.4.2. Precast Yard ...................................................................................................................16

3.5 CONCRETE SUPPLY (BATCHING PLANT) .........................................................................17

3.6 TEMPORARY JETTY .............................................................................................................18

4 SEQUENCE OF ACTIVITIES .........................................................................................................19

4.1 DREDGING ............................................................................................................................19

4.1.1. Mobilization & Installation ...............................................................................................19

4.1.2. Procedure .......................................................................................................................19

4.2 DEMOLITIONS .......................................................................................................................21

4.2.1. Diamond Thread Cutting System ...................................................................................22

4.2.2. Pecker Equipped Excavator and Demolition Hammers .................................................25

4.3 DECK ON PILES ....................................................................................................................27

4.3.1. Safety & Environmental Requirements ..........................................................................27

4.3.2. Piling Methodology .........................................................................................................28

4.3.3. Scour Protection Installation ...........................................................................................31

4.3.4. Quay Deck Construction .................................................................................................33

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 3 / 162
 4.3.5. STS Rails Installation .....................................................................................................35

4.3.6. Quay Furniture ................................................................................................................37

4.3.7. Site Clearance and Preliminary Earthworks ...................................................................37

4.4 SOIL IMPROVEMENT ............................................................................................................38

4.4.1. On Shore Soil Improvement (Terminal Areas) ...............................................................38

4.4.2. Off Shore Soil Improvement: Q1/T1 & Q2 (Slope Stability) ...........................................44

4.5 HYDRAULIC SYSTEMS .........................................................................................................56

4.5.1. Water Supply ..................................................................................................................56

4.5.2. Storm Water Drainage ....................................................................................................56

4.5.3. Waste Water System & Sewerage System ....................................................................56

4.5.4. General Procedure .........................................................................................................57

4.5.5. Specific Procedures ........................................................................................................61

4.6 ELECTRICAL..........................................................................................................................66

4.6.1. Scope Of Work ...............................................................................................................66

4.6.2. Assumptions ...................................................................................................................67

4.6.3. Technical Deviations ......................................................................................................68

4.6.4. Equipment.......................................................................................................................68

4.6.5. 69 KV Switchyard Equipment .........................................................................................68

4.6.6. MV Switchgear................................................................................................................77

4.6.7. Diesel Generator System ...............................................................................................80

4.6.8. LV Switchgear and LV Panels AC/DC ............................................................................85

4.6.9. Power and Distribution Transformers .............................................................................88

4.6.10. AC/DC Panel - Rectifier - Batteries ................................................................................96

4.6.11. High Mast Installation .....................................................................................................99

4.6.12. MV and LV Cables and Terminations ...........................................................................103

4.6.13. Reefer Sockets .............................................................................................................109

4.6.14. Cable Trays and Accessories for Earthing Lightning ...................................................113

4.7 PAVEMENTS........................................................................................................................122

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 4 / 162
 4.7.1. Definitions .....................................................................................................................122

4.7.2. Resources.....................................................................................................................125

4.7.3. Procedure .....................................................................................................................126

4.8 ROADMARKING ..................................................................................................................134

4.8.1. Resources.....................................................................................................................134

4.8.2. Procedure .....................................................................................................................135

4.9 BUILDINGS ..........................................................................................................................136

4.9.1. Main Buildings - Definitions ..........................................................................................136

4.9.2. Common Procedures ....................................................................................................142

APPENDIX – TESTING AND MONITORING PLAN ..............................................................162

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 5 / 162
1 INTRODUCTION

1.1 LOCATION
Puerto Bolívar is part of the municipality of Machala, El Oro Province, Ecuador. Puerto Bolívar is one
of the world's largest shipment points for bananas. A large part of Ecuador's banana export is shipped
through the port of Puerto Bolívar.

The location of Puerto Bolívar is shown in Figure 1 below. The location of the port is sheltered from
direct ocean waves by Jambelí Island.

In August 2016, the Turkish

port operator ‘Yilport
Holding’ (Client) signed a 50-
year concession for
operating the terminal. Part
of the concession contract is
the obligation to modernize
the port, mainly consisting of
container handling and
storage facilities.

The development is planned

in 3 phases. Only Phase 1
will be constructed in the
short term.

1.2 EXISTING LAYOUT AND SITUATION

The existing Port can handle various cargo, such as containers, general cargo, refrigerated cargo, dry
and liquid bulk. The port has a total area of 70 ha, with 2.61 ha of covered storage and 49.63 ha of open
storage. It has an administrative area next to Av. Bolivar Madero Vargas and the main entrance to the
port and the CAE (Ecuadorian Customs Corporation).

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 6 / 162
There are five berths within the Yilport concession area at Puerto Bolívar. There is a concrete finger
pier with two berths (Berths 1 and 2) of 140m length each, connected to the shore by a trestle of about
120m length. Based on local information, this berth can service vessels with maximum draught of 9.7m.

There is a marginal jetty of 372m length (Berth 3 and 4) of piled suspended deck construction,
connected to the shore by three short viaducts. Based on local information, this berth can service
vessels with a maximum draught of up to 10.6m and a displacement of up to 20,000 tonnes.

Berth 5 has a length of approximately 300m and a mooring dolphin with catwalk to the north, the
structure is a concrete deck supported by raking and vertical concrete piles, with a gentle slope of about
1 in 6 underneath, resulting in a total deck width of about 98m. The catwalk between Berth 5 and the
dolphin is supported by an intermediate pile. Berth 5 is fitted out with double cone fenders.

To the North of the existing port facilities, there is an existing jetty and helicopter platform belonging to
the naval base, as per the picture below.

1.3 NEW LAYOUT AND INTEGRATION IN EXISTING SITUATION

The port expansion as covered in this document will be developed in 3 phases. The existing layout and
the layout for the 3 phases are shown in the following drawings:

 Existing situation: BF1842-100-1002

 Phase 1: BF1842-200-2001
 Phase 2: BF1842-200-2002
 Phase 3: BF1842-200-2003

As indicated in the drawings, the quay will be developed in the 1st phase, while the 2nd and 3rd phase
include reclamation behind the quay structure bund wall.

Main buildings will be developed in line with what has been indicated on the drawings and as per below:

 Phase 1:
 Construction of Cold Storage Warehouse (first part), for storage of bananas and
shrimps.
 Phase 2 and 3:
 Expansion of Cold Storage Warehouse, for storage of bananas and shrimps;
 Construction of new Administration Building, Workshop and Container Freight Station.

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 7 / 162
1.4 PROJECT’S SCOPE
The Main Scope for the project includes, but shall not be limited to:

 Demolition works of a mooring dolphin with catwalk, the navy jetty in north side of site,
revetments and various smaller demolition works to existing structures and facilities as
required under the scope.
 Dredging works for the berth pocket
 Soil improvement offshore and onshore;
 New 450m long quay structure for berth 6, connecting to the existing berth 5, including all
furniture, services and provisions
 Scour protection and slope protection at berth 6
 Structural modifications to the quay structure of Berth 5, the pavement behind Berth 5 and
other
 existing structures as required
 Terminal, E-RTG and road pavement behind part of berth 6 and over the complete terminal,
 connecting to existing Berth 5 terminal and connecting to the public road via the gate complex
 Electrical works and data works
 Connection to the power grid and data grid
 Main substation and general power supply
 Complete reefer power supply with substations, cables, ducts, pits, etcetera
 Complete E-RTG power supply with substations, cables, ducts, pits, etcetera
 Complete STS crane power supply with substations, cables, ducts, pits, etcetera

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 8 / 162
2 METHOD STATEMENT´S SCOPE

This document aims to define the general method statements for the construction activities of the
execution of Container Terminal Development of Puerto Bolivar Expansion.

Throughout the document, specific method statement for each type of work and specific details required
are mentioned.

The document does not intend to go into detail of the activities, therefore, Safety, Environmental and
Quality issues will not be addressed either.

In the event of being awarded, all the detailed methodologies will be delivered for each of the activities
mentioned in this document.

The activities described in this document must comply as following list:

 The Technical Specifications delivered by the Engineer and the designer;

 The American and British Standards ASTM, AWS, API or others if specified in the final design;
 Drawings delivered by the Consortium’s Designer.

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 9 / 162
3 WORKING AREAS

This document sets forth contractor’s working areas of our Joint Venture to be set up for the execution
of Container Terminal Development of Puerto Bolivar Expansion.

In general, social and support facilities need to be installed on site with strategic positioning. This layout
will minimize the impact since the preliminary works will allow the position of our temporary area and at
the end proceed with landscaping the to finish the scope.

As pavements and hydraulic networks are not foreseen to be installed in the below surface in yellow,
the same will be used for the installation of the support facilities. This location will avoid facility future
relocation to give way to other activities, and in addition its central position allows for shorter distances
to the quay.

Photo 1 - Working Areas Location

This area will allow the installation of various set ups that will enable the correct operations and logistics
necessary to the works. The different set ups are as follows:

• Offices for operational staff, employer and the engineer;

• Dining room for workers;
• Bathrooms and dressing rooms;
• Warehouses;
• Temporary storage of piles and precast concrete elements;
• Dangerous waste warehouse with its respective dykes and roofs;
• Storage areas;
• Fuel and light plants;
• Concrete plant for cast-in-place elements;
• Laboratory for the sampling of concrete and aggregates.

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 10 / 162
3.1 TOPOGRAPHICAL SURVEY
Before starting the works, a general topographical survey of the Project Works will be carried out, based
on the planimetry and dimensions indicated in the engineering drawings. Together with the setting out,
all the topographic works necessary to have a representation of the terrain relief will be carried out.

The topographic works will be carried out using precision instruments and topographic implements, with
current certification of a seniority not exceeding 1 year.

3.2 LOCATION OF SITE AND SERVICES

Offices will be built for the Consortium, with all its facilities, including all its services such as electricity,
telephone, internet, heating, hygiene services, etc., in addition to the furniture that must be of quality
per the duration of the Project.

Preliminary, the 20’ Modular container has been proposed as a solution for the offices, can be two
option for the internal distribution at the offices containers:

Photo 2 - Office Containers Configuration

General Specifications:

 Walls & Ceiling wood framed R-13 fiberglass insulation and lined w/ 5/16″ Hardie Paneling™;
 10,000 BTU A/C window unit;
 100 AMP Electrical panel;
 (5) 110V (2-PLUG) Outlets (one dedicated for A/C unit);
 (2) 4ft overhead florescent lights & (1) switch;
 (2) 2ft x 3ft Windows w/ steel security bars;
 3ft side entrance steel personnel door w/ deadbolt, handle lock & drip edge;
 Paint interior (solid color, flat finish).

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 11 / 162
It’s foreseen to build the employer and engineer in the same area of the contractor’s offices, to comply
the requirement requested in §10.2 and 10.3 – Volume IV Part 1.

Both (Employer and Engineer) facilities will have the follow aspects:

Table 1 - Office Containers Estimated Needs

As a complement for the Offices there will be sanitary facilities:

The Contractor’s, Employer’s, Engineer’s and Subcontractors’ areas shall also be equipped with
bathrooms and showers for administrative personal. As well all operational support areas shall be
equipped with sanitary facilities.

All working areas shall have chemical bathrooms, bearing in mind that there is a considerable distance
from those points to the main facilities, this includes the maritime working areas (platform and barges).

Photo 3 - Chemical Wc’s on Pontoons

Note that the number of bathrooms and facilities have been calculated considering local regulations as
per the envisaged manpower.

The specifications for all sanitary and clothe changing facilities are foreseen as follows:

Shower and Bathroom Containers

 Principal area: 7 units (Males) + 1 Units (Female)

 Precast Yard: 1 unit
 Steel Yard: 1 unit
 Laboratories area: 1 unit

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 12 / 162
 Photo 4 - Shower & Bathroom Containers Configuration

Bathroom Containers (female and male)

 Contractor’s area: 2 units;

 Employer’s area: 1 unit;
 Engineer’s area: 1 unit;
 Subcontractor’s area: 1 unit.

Photo 5 - Bathroom Containers Configuration

Showers

 Contractor’s area: 1 unit;

 Employer’s area: 1 unit;
 Engineer’s area: 1 unit;
 Subcontractor’s area: 1 unit.

Photo 6 - Showers Containers Configuration

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 13 / 162
Dressing Room Facilities

 Principal area: 1 unit (female) and 6 units (male)

Photo 7 - Dressing Room Configuration

3.3 WORKERS ACCOMODATION

Accommodation for both administrative staff and operating personal has been planned in the city of
Machala near to the project area, having in mind the hotel infrastructure and possible houses that will
serve for the accommodation of the foreign personal.

3.4 PRECAST AND STEEL YARD (CASINGS AND REBAR)

The below mentioned possibilities shall remain valid for the precast and steel yard and the selection
between them will be done depending on the safe implementation of each option and supplier’s local
availability and capacity;

At this stage, the JV foresees to acquire already assembled steel casings and to stock them on site.
Steel Casing shall then be labeled and stocked accordingly before installation. However, the JV can
also elect assemble the steel casings on site, for this purpose a full stocking/assembly operation will is
foreseen to be installed. Steel plates/coil will be imported, and casings will be rolled, welded, tested and
painted on site (the full operation will be executed by a specialized supplier).

With regards to the rebar Steel Yard, the JV intends to assemble a stocking yard where the cut and
bent rebar will be stocked before assembly. Nonetheless, the JV also envisages the possibility of
acquiring full length steel rebar and executing in situ cut and bend operations followed by stocking
before installation.

It is foreseen that the precast elements shall be built off-site by a specialized supplier and brought on
site to be stocked. As an alternative, the JV can opt to assemble a full prefabrication yard and manage
the prefabrication operation on site.

The following working areas shall be put in place in addition to the steel casing and precast yards:

 In-situ Concrete and Aggregates Laboratory;

 Storage House;
 Mechanical workshop.

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 14 / 162
3.4.1. Steel Casings Yard
Steel casings are planned to arrive directly to Puerto Bolivar Port, once the casings are off-loaded, they
shall be taken to the steel stocking yard to be labeled and stocked.

A wooden beam cradle type structure will be laid along the foreseen steel casing stocking areas, the
wooden beams being at least 10 cm thick. The wooden beams shall be evenly distributed (every 4-6
m) and be in sufficient number and to avoid deformations. Given the inertia of each pilot (diameter and
thickness), the casings shall be superimposed up to 5 layers and wooden beams will placed between
each layer to prevent any damage.

Photo 8 - Steel Casing Cradle/Rack Configuration

Wooden wedges shall also be placed between each casing to prevent them from sliding/rolling while
stocked and/or when being stacked and or removed from the stack. When lifting a casing, only the
corresponding shall be removed so that the adjacent casings remain stable.

Photo 9 - Steel Casing Stack & Wedges

The casings shall be stored per length and in accordance with the pile manufacturing program, so that
the first casings that will be required are accessible thus avoiding or minimizing the number of handlings
and reduce the risk of damage.

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 15 / 162
Full length steel casings shall be transported by a set made of two dolly and a tractor and delivered to
the loading area (temporary jetty or similar facility), this shall be done as per the daily/weekly installation
needs. While performing this operation identical precautions as per before described shall be taken to
avoid possible damages.

Photo 10 - Steel Casing Transport and Off-load

A crawler crane shall load the casings from the loading facility onto transport pontoons (two pontoons
are foreseen to be used with a minimum capacity of 400-ton each) to be taken to the piling zone. The
pontoons shall be equipped with racks to secure the casings in place during transport. The racks shall
be made of wood or steel lined with rubber to avoid damage. The casings shall not be overlaid during
transportation.

All casings will be placed in the same direction on the pontoon (part painted on one side only) to facilitate
the lifting process on the working front.

Photo 11 - Steel Casings on Transport Pontoon

3.4.2. Precast Yard

As per what is mentioned in the chapter “Precast and Steel Yards” (§3.4.) above, the precast elements
are planned to be built off-site. Once delivered, the precast elements shall be checked for quality issues
and labelling accuracy upon arrival and subsequently taken to the precast yard to be stocked.

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 16 / 162
 Photo 12 - Precast Stock Yard View

Strict construction and delivery schedules shall be put in place to ensure the necessary rhythm of
delivery and guarantee the necessary foreseen stock.

When needed for deck assembly the precast elements will be loaded and transported from the yard to
the working areas by trucks per the installation requirements.

Photo 13 - Precast Beam Transport by Truck

3.5 CONCRETE SUPPLY (BATCHING PLANT)

It is foreseen that concrete supply shall be supplied from off-site batching plants and by one or two
different local ready-mix certified concrete suppliers. Nonetheless the JV also envisages the possibility
of operating a small on-site batching plant depending on the cement and aggregates availability.

Photo 14 - On-site Batching Plant Simplified Scheme

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 17 / 162
3.6 TEMPORARY JETTY
At an early construction stage, the casings will be loaded onto the pontoons from the 30 meters made
available by the Employer at the end of Berth 5.

Photo 15 - Loading Area from Berth 5

After the casings are installed a temporary loading facility shall be built on top of the already installed
piles, estimated from row A to row D, along the first 40 meters Q1. This facility will allow delivery and
loading of casings onto the transport pontoons at an early stage of the Quay construction.

This loading facility, 60-meter long stretch, will move North along Berth 6, following the assembly of the
permanent deck thus allowing the delivery and loading of casings and all precast parts onto the
transport pontoons as well as all other marine works required materials.

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 18 / 162
4 SEQUENCE OF ACTIVITIES

4.1 DREDGING

4.1.1. Mobilization & Installation

The vessels will be mobilized from their last location. All can sail on own keel with the exception of the
backhoe dredger which will be transported on a semi-submersible transport vessel. The supporting
vessels are likely to be chartered locally. The spare parts and all other supporting tools are typically
transported containerized. Upon arrival, if required, final arrangements with Local Authorities are made
for clearance. Sea fastening will be removed, and the vessels will be prepared for operations.

4.1.2. Procedure
In-survey

Prior to the execution of the works, a bathymetric pre-dredge survey will be carried out at the Dredging
Area, the Disposal Areas and covering any potential sailing routes, to verify actual (sea)bed levels and
volumes.

Photo 16 - Multibeam (left) and typical Survey set-up on board Survey Vessel (right)

The pre-dredge survey will be undertaken, using a survey vessel equipped with DGPS positioning
system, multibeam echo sounder, heave compensator and tide gauge. In dry areas, a topographic
survey will be carried out using a back-pack DGPS-RTK system. Processed data will be plotted in plan-
view drawings as well as cross-sectional drawings.

The in-survey volumes are used to determine the total scope of works, update the planning if necessary
and used to determine the monthly progress.

Dredging Operations

Join Venture PBO proposes the execution of the dredging works using a trailing suction hopper dredger,
as well as a backhoe dredger.

A trailer suction hopper dredger pumps the material from the seabed through its suction pipes and
pumps and discharges the materials in its holds. Once the hold is loaded at its maximum level, the
suction pipes are brought back onboard, and the dredger will sail to the discharging area. Once at the

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 19 / 162
discharge area, the bottom doors are opened, and dredged material is released. The material will then
settle to the sea bottom.

Photo 17 - Schematic view of a Trailing Suction Hopper Dredger during dredging operations

Photo 18 - Medium Sized Trailing Suction Hopper Dredger Lelystad

A Backhoe dredger is a barge with an excavator mounted on the deck. It is positioned using 4 spuds.
The excavated material is dumped into split hopper barges which are moored alongside. Once these
barges are filled, they will be towed to the dumping area. At the dumping area, material will be
discharged through bottom doors, just as for the Trailing Suction Hopper Dredger.

This dredger will be used for the areas near to land, as well as at greater depths where firm clay is
located.

Photo 19 - Schematic view of a Backhoe dredger during dredging operations

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 20 / 162
Out-survey

After completion of the Works an out-survey, witnessed by the Employer or it’s representative is
conducted to verify and prove that design levels have been achieved. The data is converted into as-
built drawings and submitted for approval, to the Employer or either the dedicated Engineer. Once the
out-survey is approved, equipment is demobilized.

General Measures

The deposit of sediments in the ready Zone must be controlled and the following measures must be
complied with:

 The mechanical condition of the dredge must be verified, and no excess flue gas is emitted;
 The deposit will not be made in the high seas area in the months of June to October due to
these months, the son of humpback whale transit (Megaptera novaeangliae) for its reproduction
process;
 No discharge of waste and / or discharges of hydrocarbons from the washing of tanks, bilge
water, and in general any other action capable of having polluting effects is required;
 The discharges must be homogeneous at different points within the disposal zone, avoiding
the formation of a background threshold that can alter the currents;
 Signal the sediment disposal area at sea;
 Keep track of the volume deposited in the high seas area.

4.2 DEMOLITIONS
Several structures will be demolished and removed from the site for the construction of the Expansion
of the port of Puerto Bolívar, namely:

i. The catwalk and the dolphin north of Berth 5;

ii. The naval base jetty and related structures, north of Berth 5;
iii. And Other smalls structures onshore.

Photo 20 - Structures to be Demolished

Two types of demolition procedures shall be adopted, namely:

 For items i. and ii. above, demolition shall be done by cutting with diamond thread;

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 21 / 162
  For items iii. and iv. above, demolition shall be done by using a pecker equipped excavator.

Photo 21 - Demotion Type Location

The following demolition procedures explain both methods:

4.2.1. Diamond Thread Cutting System

The system consists of a hydraulic equipment that entails a set of devices (hydraulic unit, head, pulleys,
rail and accessories) that guide a 10.5 mm diameter steel cable and has alternating discs with diamond
inlays (sintered pearls). Due to the driving force of the equipment, tension, translation and speed are
applied to the cable in friction with reinforced concrete elements, in such a way that it can cut them.

Photo 22 - Pulley system and accessories

[Link] Resources

Personnel:

• Site engineer;
• Health& safety manager;
• Worker;
• Equipment operator.

Equipment:

Drilling System and breakers

• Hammer combined;
• Combined rotary hammer.

Diamond Perforation System

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 22 / 162
 • Water tank;
• Diamond.

Cutting System with Diamonded Thread

• Thread cutting system;
• Tool Set;
• Cutting saw with thread;
• double pole with stand.

[Link] Procedure

I. The Labor Supervisor will verify that the water intakes and distribution hoses are find skilled and in
good condition.

II. The Work Supervisor will instruct the equipment operator and his assistant to open the valves of
the cooling water verifying that at the cooling points the water flow is the suitable.

III. The hand tools must be tied with ropes to the wrists of the operators and in addition, it must be
verified that the scaffolds have skirting boards throughout the perimeter of the work platform.

IV. The installation of the DS WS15 equipment includes the anchoring of directional pulleys. For this
end perforations with TE-30 rotary hammer and carbureted drill bits will be made; the rotary hammer
must have dielectric insulation, sockets and sockets must be inspected cables and personnel must
be trained in the use of rotary hammer and must have particle protection mask and hearing protectors.

V. The installation of the diamond wire in the equipment will be carried out by the operator and his
assistant wearing leather gloves. The equipment operator must verify that the length of the thread
diamond is adequate to cover the entire length of cut. Verified thread length diamond the operator will
place the connectors using a manual press.

VI. The team operator and his assistant will enter the work area with his team personal protection to
make a final verification of the feeding location of the equipment, cooling water hoses, directional
pulleys, wire position diamond and head are appropriate. This verification will be done with the
equipment disconnected from the power source (440 V generator set), it must also be verified that all
equipment start switches are turned off.

VII. The Labor Supervisor must verify that there is no person at a distance less than 3 m. of the cutting
equipment. The entire perimeter of the scaffolding around the concrete wall with safety tapes to
prevent the transit of people below the cutting area (surrounded by scaffolding).

VIII. The Work Supervisor will instruct the operator to activate the cutting equipment by means of the
control remote in order to perform a test of the equipment in progress for 3 minutes, verifying that the
equipment components work smoothly (pulleys, diamond wire, head).

IX. The Labor Supervisor will make the final verification that there are no people close to the area of
work and then give the indication to the operator of the equipment to start the cutting of the block of
reinforced concrete.

X. During the team's cutting work, the entry of people outside the task will be restricted within the work
area. Additionally, the access of any person will be restricted (including Supervisors, Work Supervisor,
Operator and Operator Assistant) to 3 m. around the team.

XI. The only persons authorized to intervene in the work area of the cutting team are: Work Supervisor,
Equipment Operator and Operator Assistant prior authorization of the Work Supervisor.

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 23 / 162
 Photo 23 - Operator Assistant in the work area

XII. When necessary to enter the work area, less than 3 m from the cutting equipment, with in order
to relocate the cooling hoses, accommodate the position of the pulleys, place steel wedges and / or
any type of intervention less than 3 m. of the cutting equipment, the person responsible for the
intervention will minimize the revolutions in the cut and communicate to the task staff so that it
performs the work with caution and constantly coordination.

XIII. Concluded the intervention of authorized personnel in the work area less than 3 m. of the team,
the staff will proceed to remove their tools, equipment or materials used and communicate to the
Labor Supervisor the end of his activities.

XIV. The Work Supervisor will inform the area staff about the end of the intervention and this will carry
out a final inspection and verification that everything is risk free and the person who intervened in the
work area has not left tools and / or equipment that can represent dangers when re-energizing the
cutting equipment.

XV. If the work remains unfinished during the day, the teams will be left with a card “Out of Service”
in the boot system, indicating on the reverse the risk at which exposes when activating the equipment.
if, on the other hand, the work has already been completed, the cut element will be removed by lifting
operation.

Photo 24 - Lifting maneuvers.

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 24 / 162
4.2.2. Pecker Equipped Excavator and Demolition Hammers
The system consists of a hydraulic excavator equipped with a hammer tool and some compressor
equipped with pneumatic hammers, to dismantle or eliminate structures which have already fulfilled
their useful life or need to take advantage of the space where it is built for a new project or construction.
In this case there is an advantage that is a controlled demolition provided that the relevant care is taken
and the appropriate techniques are used knowing the key weaknesses of the structure.

Photo 25 - Pecker Equipped Excavator and Pneumatic hammer

[Link] Resources

Personnel:

• Site engineer
• Health& safety manager
• Worker
• Equipment operator

Equipment and Tools:

• Excavator
• Pneumatic hammer for excavator
• Pneumatic hammer
• Compressor
• Shears
• Manual tools

[Link] Procedure

I. Inspect the work area before starting work, which must be totally free of water-oil, oil and any type
of sludge or chemical substance. Otherwise, the executor must immediately inform the issuer, be it
the area owner, operations personnel or the technical agency, in order to treat this crude, or chemical
substance found in the area. The sludge and sewage that may exist in the septic tanks to be
demolished must have been previously cleaned, treated and disposed of as established in the
environmental guidelines.

II. Demarcate the work area with danger tape or demarcation of the demolition area.

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 25 / 162
 III. Before, during and after each activity, you must confirm the physical condition of the people to
prevent the occurrence of accidents.

IV. Clean the work area to eliminate or control objects on the floor and avoid slipping or tripping.
Perform spraying, felling, and removal if necessary.

V. Stop activities when heavy rains and thunderstorms occur.

VI. Replaced the area to start demolition work.

VII. The pre-operational check of all the equipment and / or tools used will be carried out, verify before
they start the activity their proper functioning, if at the time of carrying out the work the conditions in
the task analysis of the activity, will be disclosed to staff.

VIII. Identification of the type of equipment to be used to demolish.

IX. The demolition may be executed using the following equipment; compressor with pneumatic
hammer and / or excavator with demolition hammer, polisher, hand tools, power tools, etc. The
demolition of concrete structures through the use of the compressor, pneumatic hammers, excavator
with demolition hammer, will be carried out like this, once the pre-operational of the equipment and
tools is carried out and if the electrical certificate issued by the electrical specialist with card is required
current professional.

X. The pneumatic compressor, excavator with demolition hammer are switched on. It should be noted
that the operator of the equipment and the guide must have ear and cup protection, mask for
articulated material, helmet, boots, glasses and safety clothing.

XI. If the compressor is used, it must be located on a stable and level surface. The operator will firmly
hold the hammer control, which by percussion will penetrate the concrete structure with its tip to the
point of completely demolishing it.

XII. If the excavator is used, the area must be cleared for its operation, it is necessary to have a person
who serves as an operational watchman who must be in communication with the equipment operator
so that in case of emergency the activities are suspended.

XIII. Once the concrete has been demolished, it is necessary to cut the existing rod using a polisher
or shear.

XIV. It should be noted that during the development of the activity the workers must have hearing
protection of insert and cup if necessary, mask for particulate material, helmet, boots and safety
clothing, face shield, gloves and breastplate. Likewise, the operator of the pneumatic hammer must
make temporary rest breaks of 10 minutes for each hour worked or according to physical capacity,
this rest includes the complete shutdown of the equipment to mitigate the impact of noise exposure.

XV. The operators of these equipment and machinery must be trained, qualified and competent to
handle them. The presence and proximity of workers close to the field of action of the equipment and
/ or machinery will not be allowed on the risk of projection of particles, blows, entrapments, and even
death.

XVI. Partially, the material resulting from the demolition (debris) will be located in an area adjacent to
the operation. Civil works assistants, by means of minor tools such as shovels and wheelbarrows, will
collect the resulting material and deposit them in the area duly indicated as provisional collection of
debris.

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 26 / 162
 XVII. The worker, through the minor tools mentioned above, proceeds to the demolition of the
concrete; you must wear permanent safety glasses, as well as masks for participating material.

XVIII. Once the demolition work is finished, the area is cleaned.

4.3 DECK ON PILES

The deck-on-pile solution consists in the construction of a reinforced concrete deck that will be
supported by deep foundation (steel casings). The deck will be made of:

 Precast pile caps;

 Precast longitudinal and transversal beams;
 Precast slabs (set on the beams);
 A cast-in-situ compression slab.

Provided deep foundation is made of steel driven casings (piles). Casings will be driven to the required
depths per the JV’s Design.

Photo 26 - Deck on Pile Layout

The connection with the deck is ensured by precast concrete pile caps which will be placed on top of
the piles. The connection between precast elements shall be done by means of cast-in-place concrete.

4.3.1. Safety & Environmental Requirements

Due to project characteristics and location, special care on safety and environmental issues during
design, planning, installation and operations shall be adopted.

Safety and environmental specific requirements are not the object of this documents and shall be
developed at a later stage and in depth after award. For this purpose, special dedicated chapters on
safety and environmental issues during piling shall be included in the safety manual.

These chapters shall be developed with the participation of all involved individuals from the design
stage and planning phases up to the final stages of installation and operation of the system (s).

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 27 / 162
[Link] Safety

Platforms and guide frame unit(s) shall be designed to ensure maximum safety to all personnel involved
in the operations. Access and egress ways including stairs and handrails shall be included.

The following safety guidelines shall be adopted:

 Detailed safety and evacuation plan to be understood by all authorized personnel working on
the piling;
 Only authorized and trained personnel shall access to the platforms and deck;
 Individual safety protection equipment shall be used always by all personnel;
 All accidents and incidents shall generate a revision in the safety plant;
 Pre-job meeting for the involved personnel shall be included at the shift start and for all shifts;
 Organization and order must be predominant in all working areas;
 Periodical inspections on all structures and equipment shall be planned, scheduled and
performed timeously, extraordinary inspections shall also be enforced;
 Pre-determined check-lists shall be verified and recorded prior every platform or crane move
between spans;
 Pre-determined check-lists shall be verified and recorded prior to the start of any activity on the
piling frame.

[Link] Environmental

All personnel allocated to the project, from design to construction stages, shall be compliant with
Environmental Company Policy and Project Plan, namely:

 Pollution Prevention Plan;

 Waste Management Plan;
 Noise Management Procedure;
 Spills Response Procedure;
 Ecological Monitoring Procedure.

Personnel involved in the construction shall be trained to all the above mentioned HSSE matters.

4.3.2. Piling Methodology

The piling broad methodology shall be as per below:

 The quay deck shall be built using movable platforms on top of the previously installed casings
(piles) as well as the adequate crawler cranes and piling frames;
 The cranes shall be able to crawl and turn while operating on top of the movable platforms;
 The working loads shall be bear by the platforms/piles.

[Link] Casing Transportation

Transportation from the stock yard to the loading area shall be done by a set 2 dolly and 1 tractor.

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 28 / 162
 Photo 27 - Full Length Casing Transport Detail

The casings shall be delivered directly to the casings loading area initially at Berth 5, to be either
installed directly from its deck (in the case of the first casings to be installed) or at a later stage loaded
onto service pontoons (while casing is to be installed from moving platforms) to be subsequently
delivered directly to the pile driving platforms.

Photo 28 - Full Length Casing Tandem Lifting Detail

These operations shall be executed in accordance to the schedule and progress of the works.

Allowance for additional length will be made for the first casings to be installed. Welding is foreseen in
case casings need to be increased in length.

[Link] Casing Driving from Berth 5 & Moving Platforms

The full number of piles along the Quay and for the Terminal Platform extension are to be installed the
following way:

1. Initial piles will be installed from Berth 5 and from land using vibrators for pile pitching and
driving down to the casings to a suitable depth. Driving then follows in the more competent soils
by using hydraulic hammers;

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 29 / 162
 Photo 29 - Full Length Casing Tandem Lifting Detail

2. Movable fixed 4-stage platforms will be assembled on top of the initial piles.

Photo 30 - General View of Moving Platforms

These platforms will consist of 4 movable platforms set parallelly side by side with variable
single-level driving guides (6 to 8) specially developed to the design/grid layout.

250ton cranes will be placed on the platforms and execute the piles by using vibrators type ICE
12/14 for pile pitching and driving down to the suitable depth followed by pile driving using
hydraulic hammers type IHC S-150 to enable reaching both the required depth and the pile
bearing capacity;

3. After the piles are driven to refusal and their cut-off to the right level is made, the crane will
move and travel between platforms displacing all the guide frames, tools and supporting
equipment into their required position as per depicted below;

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 30 / 162
 Photo 31 - Moving Platforms Displacement Principles

[Link] Pile Testing

Dynamic load testing shall be done along casings driving through PDA pile testing. Special attention
shall be granted to eave phenomenon and casing re-driving together with testing to ensure pile foreseen
bearing capacity and limit settlement.

4.3.3. Scour Protection Installation

As per BF1842-0400-1004 Volume IV, vessel data at Berth 5 and Berth 6 has been stablished as per
the following:

- Berth 5: Maersk Kowloon (50,000 dwt);

- Berth 6: 167,000 dwt (19,224 TEU).

A Concrete Mattress system solution is proposed for the slope and scour protection, the preselected
system for the project is defined as follows:

- CT 220mm Constant Thickness Mattress (Incomat) under permanently immerged areas in

horizontal sea bed. 220 mm average thickness of C24/30 micro concrete. 65 mm Ø Weep
holes. Mattress panels fabricated to suit scour protection.

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 31 / 162
 - CT 150mm Constant Thickness Mattress (Incomat) under permanently immerged areas in
slope protection. 150 mm average thickness of C24/30 micro concrete. 65 mm Ø Weep holes.
Mattress panels fabricated full slope length and to suit pile configuration. These areas is subject
to propeller action and bow thrusters during berth and unberthing.

- OH 220 mm in tidal areas. OH220 Constant Thickness Mattress (Incomat) 220 mm average
thickness of C24/30 micro concrete. Weep holes 65 mm Ø @ 1 m C/C positions. Panels
rolled out and zipped between piles. The upper section, exposed to wave action, is an open-
hole mattress (OH220) for increased permeability to allow for effective wave rundown.

Design methods are available supported by case history performance. The combination of in-situ
concrete mattress with a rock falling edge apron to the perimeter provides an effective combination for
slope protection under piled quay structures. Flex mattress concepts will also be analyzed during the
detailed design stage.

The detailed design will provide further details on the use of this solution. Final specification of the
concrete mattresses is subject to modification.

Photo 32 - Concrete Mattress OH (LEFT); Pile protection example (RIGHT)

[Link] Mattress Installation

In-situ concrete mattress for scour protection purpose shall be installed before deck construction,
nonetheless concrete mattresses can also be installed after deck installation is concluded, this allows
the possibility for damage repairing and/or mattress upgrade during the quay life span, otherwise very
difficult or even impossible when other systems are used.

Photo 33 - Mattress filling while Moored Vessel

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 32 / 162
Panels of mattress fabric are pulled out to each bay, fixed around piles and zipped to neighboring
panels. A construction method from the top of the deck is preferred, mainly to reduce the project delivery
time, but the concrete mattresses can also be installed even with moored vessels in case of early
operational scenarios.

[Link] Maintenance Dredging Suitability

Maintenance dredging over concrete mattress can be undertaken by controlled suction dredging, jetting
or suction dredging without damaging the concrete mattress.

Water injection pumping can readily be used on the in-situ concrete mattress as the system is sealed
to resist high velocity jetting. Suction dredging should be controlled to not exceed the deadweight of
concrete mattress panels and to not disturb the rock edge.

Dredging by excavator, clamshell or cutter suction dredging are not advisable due to the risk of mattress
damage.

 A minimum mattress thickness of 200mm is recommended for the areas where dredging works
may be executed;
 A minimum mattress thickness of 150mm is suggested for the areas where maintenance
dredging is unlikely.

4.3.4. Quay Deck Construction

[Link] Precast Elements Construction

Most part of the concrete structure is composed of precast elements. These precast elements (beams,
deck slab, pile plugs, etc...) will be manufactured off-site by a specialized supplier, based on drawings
and concrete formulation as per design specifications.

Photo 34 - Precast Construction Details

[Link] Precast Elements Installation

The assembly of the precast elements will be carried out by a 250ton crane working from a movable
fixed platform (like the pile driving fixed platform) The precast elements will be transported on a barge
and placed directly in their correct final position according with a logical assembly sequence.

The crane will start by installing the pile caps from the forward side of the platform (towards the pile
driving platform). Grout injection will be carried out from an independent moving grouting plant placed
on a small pontoon.

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 33 / 162
 Photo 35 - Pile Plug Installation Detail

The installation of the remaining precast elements, transversal and longitudinal beams and pre-slabs
will be done from the backward side of the platform (facing opposite side from the piling platform).

The installation sequence will be the following:

1. Beam installation shall be done taking special care of the support points on the pile caps.

Photo 36 - Beam Installation Detail

2. After beam installation is concluded, the “pile cap/beams” steel connection and formwork shall
be prepared, and inner beams/nodes concreting shall follow.

Photo 37 - Cast in Place Concrete for Beams/Nodes

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 34 / 162
 3. Following the conclusion of the “pile cap/beams” connection concreting the deck precast slabs
shall be installed on top the beams taking special care to the curing required time.

Photo 38 – Precast Slabs Placing

[Link] Compression Slab

The deck construction shall follow by placing and fixing construction rebar and in parallel all required
ducts and niches for electrical network, drainage, crane rails, crane anchoring and end-rail stops and
bollards on top of the precast slabs. The assembly of formwork shutters shall follow and concreting will
start by use of a crane and a strategically placed stationary concrete pump.

The ready-mix concrete shall be supplied from a local ready-mix plant, based on a previously approved
concrete mix, and the concrete will be transported by means of mixers to the stationary pump.

4.3.5. STS Rails Installation

[Link] General

Crane Rail installation works pertains to the provision and installation of steel rails at constructed crane
beam foundation including its necessary accessories and fixtures to its design specifications,
alignments and levels.

One (1) pair of 450-meter-long crane rail spaced 30,48m apart for the quayside STS Gantry Crane will
be supplied for this Project.

The main works involved in the crane rail installation are as follows;

 Sole plate and anchor bolt installation

 Rail and rail clip installation
 Crane slot recess filling

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 35 / 162
 Photo 39 - STS Crane Rail Installation Flow Chart

[Link] Sole Plate and Anchor Bolt Installation

Prior to the carrying out of concrete casting works for crane beam foundations, the hold down bolts of
the crane rail system are embedded. This is done using a temporary template to hold and support the
bolts into position. The alignment and level of the bolts and template are properly fixed and stiffened to
avoid any movement during concreting. After concrete casting of the crane beam foundation is
completed, the template is carefully removed for use at the next foundation. The bolts, as necessary,
are barricaded and protected from being damage.

Based on the programmed schedule of works, the installation of the sole plate is carried out; the sole
plate has been fabricated with holes the size and spacing of the previously installed hold down bolts
and is of discontinuous type. The plates are laid and inserted to the bolts and its level adjusted by
means of the hold down bolt screws. After the sole plate alignment and level are fixed, a pre-approved
high strength grouting material is injected between the concrete beam foundation and the sole plate for
bonding.

[Link] Rail and Rail Clip Installation

The crane rail installation proceeds after the sole plate installation is completed.

Pre-approved steel rails are delivered to the site and readied for installation. The installation is done by
first cleaning the surface of sole plate and making sure that no deleterious materials remains. The bases
of the crane rail clips are thereafter fixed to the sole plate by full welds, the upper part which will hold
the rail are installed later.

After the welding of the crane rail bases are completed, steel reinforced resilient bearing pads are laid
inside the space between the rail clip bases. The pads are properly aligned and leveled prior to the
installation of crane rails.

Subsequent to its installation, the crane rails are spliced to cover an entire length of rail installation area
currently prepared. It is laid above the bearing pad and fixed into alignment by rail clips inserted through
the hold down bolts of the rail.

The process is repeated until all rails and clips are installed in accordance with the construction
drawings and design specifications. During the installation work, it is constantly monitored by

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 36 / 162
instrumented survey to maintain that all required alignment and levels are within the allowable tolerable
limits.

[Link] Crane Rail Slot Recess Filling

After the completion of rail installation, the rail slot recess is filled with pre-approved materials to reduce
the recess gap and achieve an acceptable low impact from crossing vehicles.

Accordingly, the crane rail installation works will be in accordance with the construction drawings and
design specifications and comply with all the safety, environmental and quality plans being implemented
for the Project.

Photo 40 - STS Crane Rail Slot and End Stop

4.3.6. Quay Furniture

After the compression slab concreting is concluded, fenders, bollards, ladders, barriers and other
elements will be installed or other either from land or from a barge depending on the element by using
cranes and/or other suitable resources.

BOLLARDS

FENDERS

Photo 41 - Fender and Bollards Installation Details

4.3.7. Site Clearance and Preliminary Earthworks

Excavation, loading, transportation and dipping on the different areas shall be carried out at several
work locations, per the schedule and as per what is described in the technical specifications.

The following construction processes will apply:

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 37 / 162
  Project zoning and definition of elevations shall be done through topographic measurements,
transferring to the ground, through staking, the project alignments and levels.
 Site clearance, if verified necessary, can entail, cleaning and removing all local flora, in such a
way that the surface shall be fit for purpose within the whole of the project area.
 Excavation and soil selection: Cutting and excavation shall be done considering the existing
ground levels and the final required project levels. The ground that is below the required project
levels will be filled in with selected soils and the ground that is above the project levels will be
cut and excavated.
 During the cut and excavation, soil selection will be done according with the following:
 Soils suitable for filling;
 Soils not suitable for fill that will be disposed of to an offsite dumping facility.
 Suitable soils shall be transported by dumper trucks to the designated fill areas, the soil is
offloaded, spread using bulldozer and motor grader and finally compacted by layers by
compactors/steamroller

Photo 42 - Cutting, Loading, Extended and Compacting Activities

4.4 SOIL IMPROVEMENT

According to the foreseen soft soil current and final thickness, our design will require that soil
improvement techniques need to be executed to improve the soil-bearing capacity and to account for
liquefaction under seismic conditions. According to our preliminary design the soil improvement
techniques are the following:

 Onshore: Dynamic Replacement

 Offshore: Cutter Soil Mixing

4.4.1. On Shore Soil Improvement (Terminal Areas)

Photo 43 - Dynamic Replacement Execution

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 38 / 162
The Dynamic Replacement (DR) columns are formed by a heavy pounder with a weight ranging from
15 to 30 tons drops from a height ranging from 10 to 30 m on a 0.6 to 1.2 m thick working platform
prepared on the construction site using non-cohesive soil. A single column is formed by a few series of
pounding. Large diameter (1.6 to 3.0 m) columns are driven to a depth ranging from 4 to 7 m.

Following the installation of DR columns, the “ironing phase” is executed where the working platform
and the top layer of soil is compacted. This process is normally performed by using a flat-shaped
pounder with a square base. Single pounds are performed side by side at a distance equal to the
external dimension of the pounder base so that the whole improved surface area is covered. Finally,
classic compaction with the use of heavy vibratory rollers is conducted to complete the soil treatment.

Photo 44 - Dynamic Replacement Execution Process

DR columns can act as piles with an extended head for stabilization of road or rail embankments where
the columns improve the stability and increase the safety factor of the embankment. These columns
are also successfully applied to reduce the foundation settlement of commercial and industrial buildings
and to stabilize landfills.

DR columns can be constructed both in loose non-cohesive and firm soils, soft cohesive soils as well
as in organic deposits. Natural aggregates, concrete rubble, crushed asphalt and construction rubble
can be used to form the DR columns.

Photo 45 - Dynamic Replacement Technique Suitability

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 39 / 162
The parameters of the treatment such as spacing between impacts, number of drops per location,
number of compaction phases, are usually confirmed on site during the pilot test area (calibration zone)
that can include confirmatory testing such as weight penetration tests, global settlement measurement
and in-situ testing. Dynamic Compaction is performed in phases until the achievement of design
requirements, usually requiring several compaction phases with a final ironing phase of lower energy
high density drops.

Photo 46 - Dynamic Replacement Typical Phasing

Benefits

 Enhanced bearing capacity.

 A reduction in the total and differential settlements.
 An increase in the permeability allows acceleration of anticipated settlements.
 Ground bearing foundation solutions can be adopted reducing the need for reinforced
foundations.
 The displacement process creates no spoil.

[Link] Resources

Staff

 Engineer.
 Foreman work.
 Safetyman.

Personnel

 Operator crane.
 Helpers.
 Operator excavator.
 Welder.
 Mechanical.

Equipment

 Crane 80 ton or similar + Mass *

 Excavator 20 Ton.
 Bulldozer 20-30 Ton.

(*) For the construction of the Dynamic Replacement Columns (DR or also called 'plots'), a service
crane of between 80 and 150 tons is used, equipped with a hexagonal mass of between 10 and 16

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 40 / 162
tons, which is exchanged for a light dough for ironing. The construction of the plots requires, as auxiliary
equipment, an excavator and a front loader.

The masses, which are commonly used, are made of steel, generally of hexagonal section, and of
"punching" geometry to be able to direct the energy directly on the column that is constructed.

Material

The material used for the making of the granular piles be selected every project in function of the local
availability. In general, it is of granular type without select (fines percentage < 15%). However, we have
made a great number of projects with a lot variety material among which include debris material
(dimensions between 400-600mm).

[Link] Procedure

i. Preliminary.

It should have a work platform that must be flat, horizontal, drained and stable so that all the movements
of all the machines that will intervene in the dynamic replacement (material gondolas, cranes, front
loaders and excavators), are carried out, in any moment, safely and free of all obstacles on the ground.
It is advisable to have a geotextile that functions as a separation layer between the materials that make
up the natural terrain and the granular filling of the new work platform, this in order to prevent the
thickness of the new platform from decreasing due to the penetration of the latter in the natural terrain.

ii. Calibration.

A calibration will be carried out for the construction of each plot before starting the series work. As a
recommendation, it is suggested that the sea calibration zone of 25.0 x 25.0 m, in order to optimize the
following parameters, depending on the behavior of the soil:

 Execution logistics.
 Mass drop height.
 Number of strokes per plot.
 Energy.
 Volume of material to be incorporated in each plot.

Calibration zone (test zone), the following parameters are taken into account:

 Representative location (suggested area of 25.0 x 25.0 m).

 Free access.
 There should be no vegetation or obstacle.
 Stable work platform at least 1.50 m above the water level.
 The location of the four corners (grid).
 Sufficiently far from a sensitive construction or structure.

Subsequently, during the production process, adjustments to the parameters can also be made
depending on the behavior of the filler material and the energy applied.

iii. Location reference plots.

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 41 / 162
 Photo 47 - Dynamic Replacement Plots Referencing

The Project Manager / Team Leader will instruct the surveyor to location reference within the area
where he is going to work. The surveyor then draws sections within the work area by locating reference
points in a given area; subsequently, the location of the plots that are within the area delimited by the
references is plotted with the help of a tape measure.

iv. Pre-excavation.

Photo 48 - Dynamic Replacement Pre-excavation

Depending on the behavior of the soil it will be necessary or not to carry out a pre-excavation, up to
the depth of the project or as far as the soil allows. Once the pre-excavation is done, some granular
material is added in order to start the construction of the plot.

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 42 / 162
 v. Plot Construction

Photo 49 - Dynamic Replacement Construction Sequence, #1

The operator positions the mass on the point of the element to be built, and then proceeds to plot
from the work platform level.

The operator lifts the mass to the defined height and drops it to the center of the plot. This is repeated
several times in order to insert the granular material into the soil to the desired depth and compact it.
As the granular material is compacted, and it penetrates the ground, more material is added, in order
to complete the column up to the work platform level. Occasionally, if the walls of the excavation are
unstable, the necessary material may be added to fill the pre-excavation and achieve containment, and
then compact the latter with sufficient blows given by the mass. The input material is transported with
the help of a front loader.

Photo 50 - Dynamic Replacement Construction Sequence, #2

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 43 / 162
 Photo 51 - Dynamic Replacement Ironing Stage

At the end of the dynamic substitution, you should hit on the area that has already been treated, which
consists of hitting the entire surface with a light mass (hit mass) and thus terminating the treatment.

4.4.2. Off Shore Soil Improvement: Q1/T1 & Q2 (Slope Stability)

Cutter Soil Mixing Technology (“CSM”) was developed by the SOLETANCE BACHY GROUP and other
partners in 2004. The CSM soil improvement technique has now been in operation for 15 years with
excelling results both technically and economically.

The JV’s alternative solution entails soil improvement that is envisaged as depicted below and a
footprint as per the following:

 Starting at the edge of Berth 5 and extending North for approximately for 144 meters along the
future Berth 6, with average width of 95 meters and average depth of 9,50 meters;
 At the transition slope from Berth 5 to Berth 6, a 75-meter long and 10-meter wide stretch, with
4,00 meters’ average depth.

Photo 52 - CSM Soil Improvement Footprint

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 44 / 162
 Photo 53 - CSM Soil Improvement Transverse Section at Q1/T1 & Q2

The total volume of soil to be improved shall be around 132 885 m3 with a substitution ratio of 23%,
thus the effective CSM treatment shall be around 30 560 m3. The CSM treatment shall be done
executed as per the following geometrical parameters, as depicted in the picture below:

 Panel width: 0,90 meters;

 Panel length: 2,80 meters;
 Max square grid dimensions: 7,50m x 7,50m

Photo 54 - CSM treatment Panel Grid

As per what is shown above, the geometry of the exiting slope under Bert 6 at Q1 and Q2 together with
the fact that T1 is around the same level as Berth Terminal platform and that the stretch of slope from
the back of Q2 to shore is a natural under water slope, demands that CSM soil improvement be
executed by two separate workshops in parallel, using two IKIA LHDCM Rigs together with
complementary land-based and marine-based support resources.

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 45 / 162
[Link] Resources

[Link].1 COMMON RESOURCES

Mixing Tool

Photo 55 - CSM Mixing Tool

IKIA LHDCM Rig

Photo 56 - IKIA Rig Datasheet, #1

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 46 / 162
IKIA CSM Compact is the last generation of compact Soil mixing, designed and manufactured by
Soletanche Bachy, following requirements for a compact low headroom. CSM is a 40-m deep
excavating machine and its hydraulic power comes from an external power pack that can be mounted
on a carriage platform (tracks).

The CSM will be associated with the cement plant and Injection cement pump.

In addition to the usual cutter facilities, CSM is equipped with a translation (800 mm), a parallelogram
boom, a 360° turning table and the Kelly will be equipped with a turning head to allow the cutter to be
correctly positioned.

Base Carrier Dimensions

Photo 56 - IKIA Rig Datasheet, #1

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 47 / 162
 Photo 57 - IKIA Power Pack Configuration

[Link].1 LAND-BASED RESOURCES

Additional to the IKIA LHDCM Rig the following land-based resources shall be required to adequately
perform the required soil improvement.

Photo 58 - CSM Land-based support Set-up

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 48 / 162
 [Link].1 MARINE-BASED RESOURCES

One of the IKIA LHDCM Rigs and other plant such as cement silos, mixer plants and diverse pumps,
shall be mounted on dedicated flat top barge for maritime works purpose, as per the below
configuration.

This specially designed barge shall be equipped with Real Time Kinematic Global Positioning System
(RTK-GPS) for positioning purposes and with a double silt curtain for spoil and turbidity control.

Photo 59 - CSM Marine-based support Set-up

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 49 / 162
[Link] Construction Sequence and Methodology

[Link].1 LAND-BASED CONSTRUCTION METHODOLOGY

Positioning of Soil improvement rigs

For the positioning of the Soil Improvement panels a full area survey shall be done to optimize and
match land and marine grids and allow the positioning of said Soil Improvement panels. Panel setting
out shall be done by topographically set pegs or by a Real Time Kinematic Global Positioning System
(RTK-GPS) units which has the following advantages:

 Not affected by weather conditions;

 Operated at Real-time manners;
 Fully automatics;
 Easy in operation and installations;
 High accuracy (about 3 cm deviation in general).

CSM panels execution technique

 Drilling (called mix-down phase) with bentonite mud delivery from platform level. Estimated mud
volume needed 1,750 litres of bentonite per linear meter of CSM panel (section 2.80m x 1.20m);
 Bentonite slurry is to be prepared and stored for maturation during at least 12 hours. Target
Marsh viscosity = 40-45 seconds. Target density = 1.02 / 1.03;
 Once bottom of treatment zone is reached, withdrawal (called mix-up phase) with incorporation
of cement grout. Estimated volume = 790 litres of grout per linear meter of CSM panel (section
2.80m x 1.20m);
 Cement grout W/C ratio is estimated to be 0.667;
 Target density = 1.67.

The CSM tool can be divided into 3 different parts: 2 cutting wheels, a set of grout nozzles and a set of
shear blades. These shear blades are located in between the wheels, on a fixed and rigid support.

Each of the cutting wheel is powered by an embedded hydraulic motor and carries two symmetrical
drums. Each of these drums is equipped with a set of teeth on the tip of mixing blades.

For a cutting section of 2 800mm x 900mm; the cutting head is made of: 2 hydraulic motors powering 4
no. of drums. Each drum carries 6 rows of 3 mixing blades each. Each drum processes a set of 5
scrapers for a total of 20 scrapers on the cutting head.

Photo 60 - Mixing Tool Detail

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 50 / 162
 Treatment sequence

Associated construction sequence is parallel walls made of Primary/secondary panels. Secondary

panels are foreseen to bite over a minimum of 300mm into primaries on each side. Secondary panels
shall be installed no sooner than at least 12 hours after completion of both primaries.

[Link].2 MARINE-BASED CONSTRUCTION METHODOLOGY

Barge Positioning

For the working in marine conditions, the positioning of the LHDCM barge for the installation of panels
is relied on the information provided by the Real Time Kinematic Global Positioning System (RTK-GPS)
units.

Working of the GPS system

 The GPS system is a system using the RTK (Real Time Kinematic) function of deliberate survey
GPS receivers to measure continuously the position and direction of the LHDCM vessels;
 It contains a fixed base station and a mobile station with 2 receiving antennas in the working
barges. Observation data for of the longitude and latitude is transmitted between the stations
and the computer software in the GPS unit will convert these coordinate date and calculate the
deviation and the orientation of the working barge and displayed it in the monitor so that the
accurate position of the working barge can be get.

Setting up of the stations

 Set up the fixed base station on shore nearby the construction site consisting of GPS unit,
antenna, receivers, transmitting antenna and transmitter;
 Fix the mobile station on working barge consisting of GPS unit, antenna, receivers, tow set of
receiving antennas and receiver.

Positioning Procedure

Photo 61 - GPS Setting

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 51 / 162
 Photo 62 - Barge Positioning Sequence

CSM panels execution

Photo 64 - CSM Panels Installation Sequence, #1

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 52 / 162
 Photo 65 - CSM Panels Installation Sequence, #2

Silt Curtain

The barge shall be equipped with primary and secondary silt curtain systems as part of the emergency
mitigation measures if adverse in-situ environmental results are recorded during the works.

The primary silt curtain system shall be set up containing the area of the cutting tool, and the secondary
system shall be installed in a bigger area containing the entire barge if necessary. As shown below, the
primary system entails an enclosed “Box type” steel platform. This entire structure is attached to the
barge and surrounds the cutting tool.

The secondary silt curtain is composed of multiple wire ropes and fixtures around the edge of the deck.

Photo 66 - Silt Curtain Systems Set-up

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 53 / 162
 [Link].3 COMMON PROCEDURES

Cement slurry flowchart

Photo 67 - Cement Flow Chart for the Installation of CSM Panels

Monitoring System of CSM Panel Installation

The IKIA rig is equipped with a computerized monitoring system which is employed to guarantee high
quality production of panels, and to control all stages from execution to daily report generation. Batching
and injection parameters are controlled by computer and are present to provide a pre-selected volume
ratio and cement factor, which is closely related to shaft penetration rate. In turn, these data are
automatically recorded and displayed, with visual confirmation to the rig operator that they are within
the pre-selected parametric range. Full construction records are automatically generated for each panel
for all salient drilling and injection parameters.

The monitoring system is composed of a sensor section and execution management section. The
sensor section includes sensor detectors for depth, verticality, penetration and withdrawal speed,
volume of slurry discharge, wheel rotation speed, and wheel rotation motor hydraulic pressure, and the
execution management section consists of processing, monitoring and recording devices.

During execution, the monitoring system checks that the real-time data measured each second satisfy
the quality standard values registered in advance for each depth and that acceptable quality columns
are produced. If the standard values are not satisfied, alarm is issued, and changes can be made to
installation parameters.

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 54 / 162
The monitoring system indicates the technical details as per below.

Photo 68 - Monitoring system for CSM panel installation

Sampling and Testing

Core sampling and testing will be carried out by the JV. If necessary, qualified specialist subcontractor
will be employed as backup for sampling and testing works.

Scope of Work

The testing is foreseen to be the following:

 Rotary drilling and core sampling on 25% of the executed elements;

 Lab testing for Qu, Cu & E values, including report and PE endorsement.

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 55 / 162
4.5 HYDRAULIC SYSTEMS

4.5.1. Water Supply

The layout of the pipeline will be set out topographically and marked accordingly.

Excavation of trenches will be done preferentially by mechanical means and final trimming by labour
with special care to ensure that the width and depth do not exceed the maximum specified. A levelling
instrument will be used to make depth markings all along the length of the excavation. Allowance for
deeper excavation will be made to accommodate the PCC base for inspection chambers, junctions and
at collars/joints of pipes.

Pipe installation will occur as per the following:

 Markings for pipe lines and of excavation depths will be made in ground and along the lines
according to working the drawings.
 Trenches will be excavated to the required depths.
 Trench base and bedding will be prepared base for pipe laying as per the specification.
 Pipes will be laid on the prepared bedding and supported at adequate intervals.
 Under pressure leak testing will be executed for approval and issue of ‘test certificate’.
 Encasement with sand/granular material will be provided.
 Trenches will be backfilled in layers including compaction

The water distribution system will be thoroughly disinfected before being put to use. The following
simple procedures will ensure satisfactory results:

1. Flush and clean water tank(s) and distribution pipework with potable water to remove dirt and
any foreign matter.
2. Fill the tank(s) with water mixed with chlorine solution at the rate of 50 parts per million. Retain
chlorinated water in the system allowing the chlorine to spread throughout pipework.
3. Open the farthest draw-off points or drain plug/valve to draw water. Repeat the procedure till
odor of chlorine is felt at all locations when
4. Drain out chlorinated water and fill the system with potable water.

4.5.2. Storm Water Drainage

The design location of the proposed drainage is shown on detailed design drawings.

Construction of a storm water drainage system normally includes:

 excavation, including preparation of foundations for box culverts, supply, bedding, laying,
installation and jointing drainage structures;
 provision of anchoring systems including anchor blocks;
 supply, placing and compacting select fill;
 supply, placing and compacting granular and geocomposite material at weepholes; and
 supply and placing subsurface pipes and filter fabric at pits, headwalls and wingwalls

4.5.3. Waste Water System & Sewerage System

The layout of the pipeline will be set out topographically and marked accordingly.

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 56 / 162
Excavation of trenches will be done preferentially by mechanical means and final trimming by labour
with special care to ensure that the width, depth and gradients are according to the specified. A levelling
instrument will be used to make depth markings all along the length of the excavation. Allowance for
deeper excavation will be made to accommodate the PCC base for inspection chambers, junctions and
at collars/joints of pipes.

Pipe installation will occur as per the following:

 Markings for pipe lines and of excavation gradients will be made in ground and along the lines
according to working the drawings.
 Trenches will be excavated to the required depths and gradients.
 Trench base and bedding will be prepared with the correct gradient for pipe laying as per the
specification.
 Pipes will be laid down according to specified gradient.
 Hydraulic/smoke test will be done for approval and issue of ‘test certificate’.
 Encasement with sand/granular material will be provided.
 Trenches will be backfilled in layers including compaction

4.5.4. General Procedure

These works will be carried out at the same time that the excavations, for this purpose, excavators
and dump trucks will be available for the removal of debris, among others; Parallel to the excavations
the filling of the ditches with imported loan material will be carried out to improve the soil using a
double drum roller; Likewise, transportation, laying, hydration, and compaction equipment (Dump
Trucks, Roller and Tank) will be available; filling that will be done by properly compacted layers.

Excavations will be carried out in the established places as indicated in the contractual documents,
the appropriate excavation ditches will be carried out, special care will be taken to place the respective
signs and preventive signs to avoid accidents, for this activity there will be trained personnel which
will supervise that everything is carried out safely and correctly.

The material will be collected in a clean, dry and delimited area in such a way that it represents a
safe area of transport for the public and the equipment.

The placement of filler material will be carried out with a front loader or backhoe loader or a bobcat
(this will depend on the accessibility of the equipment to the filling area), which will extend the material
in horizontal uniform layers according to what is stipulated in the plans and accessories. In the
backfilling areas that cannot be accessed with previously selected equipment, the placement is done
manually with the use of trucks placing the material in spaced piles, then proceed with the extended
manual.

Any contaminating material and / or that does not belong to the place and that could damage its
technical characteristics will be removed immediately before starting the compaction.

The backfilling layers will be according to technical specifications where the percentage of
compaction of the thickness filling or work specifications is indicated. In our environment, the
specifications average layers of 20 to 30 cm, except in the case of some other general specification.

The Site Engineer and QA/QA manager will be responsible for controlling and organizing the
equipment that will be used to determine the characteristics of the landfills and carry out and
coordinate what is necessary for the work to be carried out within the framework of respectful safety
as well as what is necessary in what respects spare parts and fuel for equipment.

The operators of the equipment will be trained to carry out the work and know all the risks included
in the activity.

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 57 / 162
 Photo 69 - Excavations Works for Pipe Installation

For the coating layer, it is essential to consider a distance between the surface to be compacted and
the existing network; these parameters must be defined in the designs.

At the edges, joints, corners in which the use of the roller is impossible to be used, with the employer's
acceptance, the compaction with Vibro rammers that meet the specifications established for this
purpose and that are in optimal working conditions.

Each layer will be moistened, without saturating it, with clean water before starting the compaction
process; this with the application of improving the adhesion of the fines of the material.

To dispose of the debris and eviction of material, the approval and/or location of the dump is
requested to the Inspection previously to the use of the material it should be tested in exterior and
approved laboratory, in order to confirm the quality of the soil or improvement material to be used

The sequence of all excavation operations is required, this must be such that it ensures the use of all
the materials suitable and necessary for the construction of the works indicated in the project plans
or indicated by the inspection.

For the activities concerning the connections, the health networks will continue in parallel so that
progress is made according to schedule.

For the installation of the chambers, once the respective excavation and improvement of the soil have
been carried out, the steel and concrete used for this purpose will be done following the regulations
required in the employer requirements, all the materials used will have quality standards for the
respective installation of it.

Recognition and delimitation of the work area with stakes, plastic mesh and danger warning tape.
Additional warning signs are placed in places visible to the passer-by and drivers.

To strengthen the stability of the walls, provided that the excavation depth exceeds 1.50m, it must be
placed in accordance with the technical specifications established for this purpose; except in the case
that the land is of a firmness that allows working without the placement of fixing, this last action must
be accepted by the employer.

If the casting dimensions of the chambers require excavations to be carried out at considerable
depths, land cuts will be made that allow the implementation of such slopes that guarantee the
stability of the sidewalls of the excavated terrain.

Levelling and compacting the foundation ground we proceed to the construction of the blind concrete
layer that will act as a cleaning bed for the structure. The area covered by this material will be greater
between 0.05m to 0.10m along the entire perimeter of the area of the chamber slab to be built on-

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 58 / 162
site.

The required steel will be placed on the foundation slab and chamber walls, according to the design
plans. The formwork of the foundation slab and the perimeter wall is made; according to the design
plans.

Photo 70 - Chamber Execution Sequence, #1

The pre-mixed and/or mechanical concrete will be poured, as appropriate, which will comply with the
technical specifications established in the design drawings. This process will be executed as many
times as necessary until reaching the required height of chamber construction and between each
stretch of concrete, the additives and materials that the design plans indicated will be placed.
(Binders, PVC tapes, etc.)

Once the concrete has been poured into the structure, the needle vibrator will be implemented.

Once the strength of the concrete required in the design drawings and technical specifications has
been reached, the next step is to decouple the walls of the chamber and then cover the outer part of
the walls with bitumen paint. The fixing of the entrance ladder to the chamber will be carried out by
means of a mechanical anchor (expansive bolts) or as indicated in the design drawings.

Photo 71 - Chamber Execution Sequence, #2

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 59 / 162
Once the height of the axis of the hydraulic assembly is defined, the pipe passage will be left on the
walls of the chamber, using wood formwork embedded in the concrete or block wall for this purpose.
The openings will be of dimensions and sections very close to those of the pipe to be assembled and
the sealing will be carried out according to what is established in the design plans and technical
specifications established by the customer.

The process continues with the assembly of the formwork of the upper one (in case of being
embedded in the walls of the chamber) and subsequent placement of the corresponding
reinforcement according to the plans.

The concrete order will be poured to reach the required level. The manufacture of
removable/removable slabs is carried out separately and according to the details.

The placement of the entrance cover to the camera is carried out according to what is established in
the design drawings. The metal welding works will be carried out in the camp located at the base of
the work; following design specifications and materials.

Photo 72 - Chamber Execution Sequence, #3

At the end of the work process, an interior and exterior cleaning will be carried out to present the
finished structure. For the construction of curb, in general, the subgrade or foundation bed must be
completed in accordance with the slope and the cross-section stipulated in the project. Before laying
the concrete the surface of the foundation must be dampened and well compacted.

All soft or unstable material must be removed to a minimum depth of 15 cm. under the level of the
foundation of the ditches, and it will be replaced with granular material of such quality that, when
wetted and compacted, take a suitable foundation base.

The formwork will be smooth and lubricated on the side in contact with the concrete and on the upper
edge, it must be rigid enough to withstand the pressure of the plastic concrete, without deforming. It
will be installed with the stipulated slopes, dimensions and alignments and will be firmly maintained
by stakes, clamps, braces and braces that are necessary. The formwork of the exposed wall of the
ditch curbs and curbs with reduced height for the construction of access ramps should not be
removed before the concrete is set, but should be removed within six hours of placing the concrete
to be made at the finish

Expansion joints of 8 to 10 mm will be left wide in the curbs, with a spacing of 3.5 meters and on both
sides of the structures, the joints will be filled with material that meets the requirements stipulated in
section 806 of the General Specifications for the Construction of Roads and Bridges of the MOP.
001-F-2002 and must be perpendicular to the curb line.

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 60 / 162
Before removing the formwork, the upper surface must be smoothed, using a suitable steamroller,
giving it a uniform finish and maintaining the slope and specified cross-sections.

Immediately after removing the formwork, the upper surface and the faces that are to be visible must
be smoothed, the edges should be rounded as indicated by the plans using a suitable steamroller,
giving it a uniform finish and maintaining the specified slope and cross-section. After smoothing, you
have to give them the final finish by passing a fine broom with movements parallel to the curb line

4.5.5. Specific Procedures

[Link] Excavation

Unless otherwise shown on the drawings, the pipes shall be laid in trench conditions.

The width of trench excavations for pipelines must be in accordance with the specifications and in
accordance with the specified tolerances.

Extended excavation will be done for drainage structures other than pipes so that, at all points on the
walls of the structure, the clear width between the structure wall and the face of the excavation is at
least 300 mm or one third of the height of the face of the excavation, whichever is the greater.

Where inadequate foundation material is found it will be replaced with materials from cuttings, or with
other acceptable material and compact to the specifications requirements

[Link].1 Resources

Materials:

• Wood poles
• Wood board (ODB type)
• Steel board

Personnel:

• Superintendent
• Site engineer (yard)
• Site engineer
• Quality control manager
• Health & safety manager
• Worker
• Equipment operator

Equipment and tools:

• Excavator
• Back hoe
• Dump truck
• Bob cat
• Hand tools
• Mechanical jacks

Test: No apply

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 61 / 162
 [Link].2 Procedure

i. Survey benchmarks shall be set-out by Land Surveying crew.

ii. Determine trench dimensions (Length, Width and depth).
iii. Excavations less than 1.3 meters in depth may not require this degree of protection if
examination of the ground by a competent person provides no indication of a potential cave-
in.
iv. Excavated material shall be stored at least 2 meters from the edge of the excavation and hard
hats will be worn by all workers at the site when work is in progress.
v. A stairway, ladder, ramp or other safe means of exit shall be located in trench excavations that
are 1.30 meters or more in depth in case of manual excavation.
vi. If an adverse condition develops, the excavation must be re-inspected and confirmed safe
before work may resume.
vii. On any excavation where depth is expected to exceed 1.3 meters or where unstable soil is
likely to be encountered, shoring or shielding equipment that will be used in case of manual
excavations.
viii. Daily inspections of excavations, the adjacent areas, and protective systems shall be for
evidence of a situation that could result in possible cave-ins, indications of failure of protective
systems, hazardous atmospheres, or other hazardous conditions.
ix. Water control may involve the relatively simple removal of small amounts of water at the bottom
of an excavation by manual or electrically driven sludge pumps.

[Link] Pipe Installation

Perforated drains

Perforated drains will be excavated (including topsoil) to the dimensions shown on the drawings.

Inadequate foundation material for perforated drains striped and dealt with in accordance with the
requirements of the specifications.

Any inadequate foundation material from the foundation area will be removed and adequate fill material
will be applied and compact to the requirements of the specification. Surplus materials from the
construction will be dealt with in accordance with the specification.

Concrete lining will be done according with the drawings Lining installation will be done in accordance
with the design and with the recommendations in the specifications.

Adequate movement joints will be built according to the design and specifications in order to control
movement and cracking in concrete lining.

Open Drains

Open drains will be excavated (including topsoil) to the dimensions shown on the drawings.

Inadequate foundation material for open drains will be cleared, grubbed and striped of topsoil where
construction of an earth structure is required to form an open drain, and dealt with in accordance with
the requirements of the specifications.

Any inadequate foundation material from the foundation area will be removed before commencing to
place material for the earth structure. Construct of the earth structure will be done in layers not
exceeding 200 mm in depth, and compact to the requirements of the specification.

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 62 / 162
Surplus materials from the construction of open drains will be dealt with in accordance with the
specification.

Concrete lining will have a minimum compacted thickness measured at right angles to the surface of
the lining. Wire mattresses will only be used where shown on the drawings. Lining installation will be
done in accordance with the design and with the recommendations in the specifications.

Adequate movement joints will be provided according to the specifications in order to control cracking
in concrete lining.

Precast Concrete Pipe Structures

Installation must be in accordance with the specifications and unless otherwise specified, pipe laying
will commence at the outlet end and proceed upstream.

All foreign matter will be removed from inside and outside of pipes before laying.

Where “Embankment Installation” condition is specified, prior to commencement of placing bedding and
laying pipes, compact embankment fill will be placed to a height above the top of the bed zone of at
least 0.7 times the external diameter of the pipe and for a minimum lateral distance outside each trench
wall of 2.5 times the external diameter of the pipe.

During installation, an alternative waterway area shall be provided.

Where “Trench Installation” condition is specified for pipes in an embankment, the embankment to the
underside of the Selected Material Zone will be completed prior to the commencement of the
excavation.

Pipes will be laid with the socket end placed upstream.

Anchor blocks will be provided at a spacing defined by the design and according to the specifications,
with a defined maximum spacing and at bends or junctions for all storm water pipes laid on a grade
exceeding 20% and where shown on the drawings. Anchor blocks will be built as per the drawings and
in-situ concrete will be placed directly against all faces of the keys in the sides and base of the trench

[Link] Backfill of Trenches and Disposal of Excavated Material Surplus

Trench backfill will be done with material excavated from the trench where it is deemed to be suitable
for backfill, otherwise materials from cuttings or other material acceptable will be used and compacted
to the requirements of the specification.

Disposal of any surplus excavated material will be done on site for embankments construction or at
other locations within the site or alternatively off site in accordance with the specification.

[Link].1 Resources

Personnel

• Superintendent
• Site engineer (yard)
• Site engineer
• Quality control manager
• Health & safety manager

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 63 / 162
 • Worker
• Equipment operator

Equipment and tools:

• GPS based total station

• Hand operated tamper / vibratory plate compactor
• Roller
• Dump truck
• Excavator
• Motor grader
• Nuclear densimeter

Materials:

• Approved backfill.

Test:

• 3 Density tests per 500 m2 shall be done (each layer) and all fill shall be compacted to not less
than 80% Modified Proctor density and will be test by a qualified geotechnical specialist using
a nuclear densimeter.

[Link].2 Procedure

i. Location of facilities shall be directed by land surveying crew according to set up layout.
ii. Surveying benchmarks shall be set-out by Land surveying crew.
iii. According to the location to be backfilled and compacted, the material will be placed, in uniform
layers to a depth no longer than 250 mm and compacted using (depending of each case) a
hand operated tamper, plate compactor or roller compactor until reaching level indicated in
drawings and the density solicited. (In places that do not allow the use of heavy machine to
compact, the layers should not be made deeper than 150 mm)
iv. In any case the Contractor must take care the Proctor test results and monitor the moisture of
the material prior to the compaction and in the middle of the process to obtain an optimal
compaction by layer.
v. After the compaction of each layer a surveyor team will record the levels to be able tracking all
the process.

[Link] Manholes (Chambers)

These structures shall not be installed later than 14 days after the installation of associated pipes,
perforated or open drains.

An isolation joint will be Installed where a drainage structure will abut a structure or concrete pavement.
The isolation joint will have width and performance according with the specification.

Base slabs for precast reinforced concrete manhole and gully pit type structures will be made of cast
in-situ reinforced concrete, cast on a blinding layer of 50 mm thick plain concrete. Concrete work,
including reinforcing steel and other embedded items, for cast in-situ invert slabs and link slabs will be
executed in compliance with the specifications.

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 64 / 162
Precast units will be installed in accordance with the specification and the manufacturer’s
recommendations.

After the installation of the precast elements the transverse joint between adjacent elements will be
sealed all around with a self-adhering membrane as per design and specifications requirements. Lifting
holes will be sealed to prevent the ingress of materials as well as the cut of lifting hooks and the coating
of the exposed steel to prevent corrosion.

In each junction box, gully pit, drop structure, etc deeper than 600 mm, an individual-rung ladder will be
installed (step irons) on one internal wall for the full depth of the structure. The top of the uppermost
rung must not be more than 600 mm below the top of the pit. The top of the bottom rung must not be
more than 500 mm or less than 300 mm above the invert of the pit

[Link].1 Resources

Personnel:

• Superintendent
• Site engineer (yard) Site engineer
• Quality control manager Health & safety manager Worker
• Operator

Equipment and tools:

• Crane set
• Forklift set
• Steel bar cutter
• Teel bar bender
• Concrete truck mixer
• Concrete pump
• Plug-in vibratory rod
• Mechanical jack

Material:

• Rebar fy 4200 kg/cm2

• Concrete (320 kg/cm2)
• Plywood HR

Test:

• Burst test (for concrete 320 Kg/cm2)

• No destructive resistance test (sclerometer)

[Link].2 Procedure

i. The reinforcement bars for the manholes, cover lids and cover plates shall be previously cut
and bent at the rebar workshop and ensemble together according to the drawings and the
construction requirements
ii. The material of lifting hook for manholes is φ25mm round bar. It will be placed inside the rebar
cage of the manhole walls, complying with the cover of the manholes, at the end of the first
stage concrete pouring, which is 35 cm from bottom of the cover plate, after the place on site

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 65 / 162
 maneuver the second concrete pour stage will take place, the lifting hook will be cut after the
manhole installation. Before cutting it, the concrete around will be marked 2 centimeters around
and then break it. After this prior procedure, the hooks will be cut using blowtorch. Thus, it is
ensuring the second stage concrete has enough cover to avoid issues where the lifting hook
was.
iii. The hols for the connection with the pipe must be made according to the design specification
and in any case the hole must have a cross reinforce around the hole to avoid cracks a tension.
iv. The formwork to be used on this work will be made of plywood and square wood mold for all
precast elements. The formwork is estimated to be reused for at least 3 times or less if the
material is not in good conditions.
v. Once formwork and embedded elements installation is finished, supervisor shall carefully
perform inspection to ensure that it is consistent with the design and quality control
specification, the pouring concrete will start using a concrete pump and a Φ50 or Φ30 plug-in
vibratory.
vi. The first stage concrete pouring will be placed in precast yard, it is 35 cm from top of the cover
plate, a second concrete poring will be made on site (this is made to avoid any abortive job and
be able to calculate the exactly slope or finish level of the pavement)
vii. The curing process will take place in the precast yard, this process consists in cover the element
with all the formwork walls with geotextile and sprinkle water, keeping wet the manhole. The
first 7 days after formwork removal the concrete surface will be sprinkled with water and
covered with geotextile. The curing geotextile shall be applied after the concrete surface has
received the specified finishing treatment. After this period, the element will be sprinkled with
curing compound, moved to storage and sprinkled again after it is set on its storage place.
viii. When manhole precast strength reached required specified characteristic strength. We will use
the Crane to hoist these manholes and transport to storage area.

4.6 ELECTRICAL

4.6.1. Scope Of W ork

 Switchyard Equipments for the 69 kV incoming line at the Main Substations

 Main Substation
 Generation System
 Reefer Substation RS4
 Reefer Substation RS6
 ERT & Reefer Combined Substation ERS3
 ERT & Reefer Combined Substation ERS5
 ERTG Container Substation ER7 and ER8
 CSW Substation
 Fire Pump Station
 Reefer Rack Equipment
 Crane Pit equipment
 CCTV
 Gate OCR System
 Crane OCR system for 4 cranes
 Fiber Optic System
 Scada System

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 66 / 162
  Cabling,
 Earthing,
 Lightning Protection,
 Ilumination
 Cable Trays

4.6.2. Assumptions

 Electrical scope starts at the incoming gantry of the 69 kV Line

 No separate training program, Employer is encouraged to actively participate in the
testing and commissioning stage to get learning on the job.
 Temperature rise, Noise, NLL, LL, PD and Lighting impulse test only on one transformer
per type.
 Power factor requirement at point of coupling with grid is 0.9
 CE marking not required since equipment not used in Europe
 Fuel quality as per commercial use Vehicles
 Existing Generator substation building
 Has automatic louvers for the 8 new positions
 Has fire resistance walls of 60 minutes as per the RFQ (or could be made
60-minute fire retardant)
 Has already installed 2 full set of DG (operating condition)
 Control system only for 2 DGs
 The existing MV Switchgear has 2 bays we can use to connect 2 DGs
 The existing MV Switchgear can be extended with an additional 6 bays
 3 spare day tanks available
 2 step up trafos available
 Space for the additional 8 DGs available
 Space for external fuel tanks available
 All Buildings have a power factor at the LV connection of 0.95
 Reefers have a power factor before compensation of 0.75
 STS have a power factor of 0,98 at 13.8 kV connection point
 ERTG have a power factor of 0.98 at 660V connection point
 STS and ERTG have a max THD V of 5% and THD I of 2%
 HV test during SAT is limited to a LIFE test with applied voltage
 HV test during FAT is limited to the relayed IEC standard tests
 LV panels behind the transformer are form 4a incomer and form 3b outgoing (above
250A)
 LV distribution panels are form 4a incomer and 2b outgoing
 Temperature rise test for LV Panels not included, however typical test report for similar
unit will be submitted.
 Light poles have lowering crown, not canting mechanism – 2 drivers in total for the entire
project to bring headframes down
 Generator sets based on Prime Power Rating 2200 kW
 The requirement for Power Transformers do not exist in EN 50464-1. Normal design is
applied
 CCTV
 We have assumed that the existing Video Management System is Milestone with

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 67 / 162
 X protect Corporate license. Hence no separate base license is considered. Only
additional Cameras.
 We have assumed that existing Monitors and Workstations would be used for
monitoring of new cameras as well and hence our offer don’t include separate
monitoring equipment
 Fuel consumption requirement shown are for a 3200 kW PRP not for 2250 KW PRP.
 STS Crane should have a 300 Lux and compatible PLC for proper OCR working
 Employer will provide resources to operate Cranes & drive trucks with test containers for
commissioning of the OCR system

4.6.3. Technical Deviations

 Voltage transformer do not have fuses.

 Outdoor LV panels are IP 66 (not IP 67 since that is for underwater applications)
 Reactors for power factor compensation are 12,5% not 14% since not typical.
 Tap changer ABB Type, not Reinhauser
 60 dB (A) at 2 meter at full load for noise from transformers and generators is
extremely low. Values can be confirmed after detail engineering
 Load step of 2 MW per generator within the envelop of +-10% in voltage and +-5% in
frequency is not possible with a 2200 kW generator. We do however confirm this
possibility with several generators in parallel.

4.6.4. Equipment
High voltage Switchgear ABB
Medium Voltage Switchgear ABB Unigear for Main SS 25k – 2500A Busbar Medium
Voltage Switchgear ABB Unisec for Others SS 20k – 630A Busbar Power
Transformers ABB
Distribution Transformers ABB
Low Voltage Switchgear Main ABB Artu K (similar to MNS)
Low Voltage Switchgear Distribution ABB Gemini
Reefer Outlets ABB (Mipco is now ABB)
Alternator ABB
Scada ABB
Lighting fixtures Philips
Crane Connection boxes Conductix
Generator Cummins
Medium and Low Voltage Cable General Cable

4.6.5. 69 KV Switchyard Equipment

In order to comply with project´s requirements and engineering design, it is necessary to supply and
install 69 kV Switchyard Equipment.

[Link] Activity

 Movement of personnel using means of transport

 Personnel movements on foot

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 68 / 162
  Pick-up of materials from storage.
 Removal of packaging prior to installation
 Inspection of inside floor of the building
 Marking out on floor for PASS and yard equipment positioning and
installation of anchoring on floor
 Positioning and assembly of PASS and yard equipment Modules
 Laying of secondary cables for electrical connections of the PASS
and yard equipment Modules
 Installation of secondary instruments of the PASS and yard equipment Modules
 Primary steel/copper installation and connection of the PASS
and yard equipment Modules
 Installation and connection of connecting cables of the PASS
and yard equipment Modules
 Installation and connection of secondary earthing of the PASS
and yard equipment Modules
 Inspection of cable connection of PASS and yard equipment Modules
 Treatment before restoring SF6 Gas for PASS Module
 Primary steel/copper installation and connection of PASS and yard
equipment Modules
 Installation and connection of connecting cables of PASS and yard
equipment Modules
 Installation and connection of secondary earthing of PASS and yard
equipment Modules
 Inspection of cable connections of PASS and yard equipment Modules
 Restoration of SF6 gas to nominal pressure
 Precommissioning tests
 Checks, tests and inspections according to doc. "QUALITY CONTROL
PLAN – ERECTION"

[Link] Resources

Equipment

 Forklift truck
 Truck-mounted crane
 Mobile scaffolding
 Torque wrenches
 Mechanic's tool box
 Electrician's tool box
 Assembly accessories
 Folding resin ladder with non-slip aluminum rungs

[Link] Procedure - Tasks, Hazards, Consequences and Control Measures

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 69 / 162
 Task Hazards Consequences Control Measures
Description

° Inadequate ° Serious injuries Ensure that:

Movement of risk (fractures,  works conducted in places exposed to
personnel & assessment amputations) extremes of temperature are adequately
materials ° Back injuries managed through a Heat and Cold Weather
° Extreme weather ° Fall into open holes Working Procedure
SAFELY,
conditions ° Fall from heights  all works, including those carried out
using means ° Impact with moving
of transport by contractors, are adequately risk
objects assessed, supervised and executed
° Impact with falling
 all high-risk activities are controlled by
objects
a last minute / point-of- work risk
assessment before starting works
° Injury to third parties

SAFELY ° Inadequate risk ° Serious injuries Ensure that:

assessment (fractures, □ works conducted in places exposed to extremes of
Personnel amputations) temperature are adequately managed through a
movement on ° Extreme weather Heat and Cold Weather Working Procedure
foot conditions ° Exposure to UV-radiation □ all works, including those carried out by
contractors, are adequately risk assessed,
supervised and executed
□ all high-risk activities are controlled by a last
minute / point-of- work risk assessment before
starting works
° Sharp edges ° Serious injuries Ensure that:
Withdrawing and moving (fractures, □ works conducted in places exposed to extremes of
materials from parts amputations) temperature are adequately managed through a
the stores ° Open holes ° Back injuries Heat and Cold Weather Working Procedure
° Inadequate ° Fall into open holes □ all works, including those carried out by
ABB supervision ° Fall from heights contractors, are adequately risk assessed,
° Working at ° Impact with moving supervised and executed
heights objects □ all high-risk activities are controlled by a last
° Platforms, ° Impact with falling objects minute / point-of- work risk assessment before
ladders and starting works
scaffolding ° Injury to third parties
° Lifting
operations
° Cranes, fork
lifts, etc.
° Damaged or
defective PPE for
mechanical

works

° Sharp edges ° Serious injuries Ensure that:

Removal of and moving (fractures, □ works conducted in places exposed to extremes of
packaging parts amputations) temperature are adequately managed through a
prior to ° Open holes ° Back injuries Heat and Cold Weather Working Procedure
installation ° Inadequate ° Fall into open holes □ all works, including those carried out by
ABB supervision ° Fall from heights contractors, are adequately risk assessed,
° Working at ° Impact with moving supervised and executed
heights objects □ all high-risk activities are controlled by a last
° Platforms, ° Impact with falling objects minute / point-of- work risk assessment before
ladders and ° Injury to third starting works
scaffolding parties
° Lifting
operations
° Cranes, fork
lifts, etc.
° Damaged or
defective PPE
for
mechanical
works

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 70 / 162
 ° Inadequate risk ° Serious injuries Ensure that:
Inspection of assessment (fractures, □ operations are conducted at the lowest possible level
inside floor of ° Lone working amputations) □ lifting equipment fit for tasks is used to avoid manual
the yard ° Inadequate ° Back injuries handling
ABB supervision ° Fall into open holes □ all loads are fastened securely in line with
° Damaged or ° Impact with falling objects manufacturers' instructions
defective PPE for ° Injury to third □ when working at heights collective fall protection
electrical works parties (scaffolding,
° Manual nets, railings) is mounted before starting works
handling □ ladders are properly selected and used
□ only competent certified scaffolders erect, dismantle
and
inspect scaffolding
□ scaffolding can be neither moved from its place of
installation (block the casters) nor climbed
□ all machinery with moving parts are sufficiently
guarded / interlocked and only competent operators
operate / maintain it in line with the manufacturers'
instructions
□ all openings are covered with unbreakable
material, barricaded and signage is in place
□ all lifting equipment is regularly inspected as per
maintenance
schedules
□ only competent and certified lifting operators operate
lifting
equipment
□ all works, including those carried out by
contractors, are adequately risk assessed,
supervised and executed
□ working at heights is under permit to work system
□ only authorized personnel is present in the lifting area
during
lifting works and the area is barricaded / signed
□ all high-risk activities are controlled by a last minute /
point-of- work risk assessment before starting works
□ PPE in good condition for the identified tasks is made
available
and all personnel are trained in its use and maintenance
fall arrest PPE (lifelines, harness, etc.) are worn when
working at heights
° Inadequate risk ° Serious injuries Ensure that:
Marking out assessment (fractures, □ operations are conducted at the lowest possible level
on floor for ° Lone working amputations) □ lifting equipment fit for tasks is used to avoid manual
PASS and ° Inadequate ° Back injuries handling
yard ABB supervision ° Fall into open holes □ all loads are fastened securely in line with
equipment ° Damaged or ° Impact with falling objects manufacturers' instructions
defective PPE for ° Injury to third □ when working at heights collective fall protection
positioning
electrical works parties (scaffolding,
and
° Manual nets, railings) is mounted before starting works
installation of handling □ ladders are properly selected and used
anchoring on □ only competent certified scaffolders erect, dismantle
floor and
inspect scaffolding
□ scaffolding can be neither moved from its place of
installation
(block the casters) nor climbed
□ all machinery with moving parts are sufficiently
guarded / interlocked and only competent operators
operate / maintain it in line with the manufacturers'
instructions
□ all openings are covered with unbreakable
material, barricaded and signage is in place
□ all lifting equipment is regularly inspected as per
maintenance schedules
□ only competent and certified lifting operators operate
lifting
equipment

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 71 / 162
 □ all works, including those carried out by
contractors, are adequately risk assessed,
supervised and executed
□ working at heights is under permit to work system
□ only authorized personnel is present in the lifting area
during
lifting works and the area is barricaded / signed
□ all high-risk activities are controlled by a last minute /
point-of- work risk assessment before starting works
□ PPE in good condition for the identified tasks is made
available
and all personnel are trained in its use and maintenance
fall arrest PPE (lifelines, harness, etc.) are worn when
working at heights
° Inadequate risk ° Serious injuries Ensure that:
Positioning assessment (fractures, □ operations are conducted at the lowest possible level
and assembly ° Lone working amputations) □ lifting equipment fit for tasks is used to avoid manual
of PASS and ° Inadequate ° Back injuries handling
yard ABB supervision ° Fall into open holes □ all loads are fastened securely in line with
equipment ° Damaged or ° Slipping, triping, falling manufacturers' instructions
defective PPE for ° Impact with falling objects □ when working at heights collective fall protection
Modules
electrical works ° Injury to third (scaffolding,
° Manual parties nets, railings) is mounted before starting works
handling □ ladders are properly selected and used
□ only competent certified scaffolders erect,
dismantle and inspect scaffolding
□ scaffolding can be neither moved from its place of
installation
(block the casters) nor climbed
□ all machinery with moving parts are sufficiently
guarded / interlocked and only competent operators
operate / maintain it in line with the manufacturers'
instructions
□ all openings are covered with unbreakable
material, barricaded and signage is in place
□ all lifting equipment is regularly inspected as per
maintenance
schedules
□ only competent and certified lifting operators
operate lifting equipment
□ all works, including those carried out by
contractors, are adequately risk assessed,
supervised and executed
□ working at heights is under permit to work system
□ only authorized personnel is present in the lifting
area during lifting works and the area is barricaded /
signed
□ all high-risk activities are controlled by a last minute /
point-of- work risk assessment before starting works
□ PPE in good condition for the identified tasks is made
available
and all personnel are trained in its use and maintenance
fall arrest PPE (lifelines, harness, etc.) are worn when
working at heights
° Inadequate risk ° Serious injuries Ensure that:
Laying of assessment (fractures, □ operations are conducted at the lowest possible level
secondary ° Lone working amputations) □ lifting equipment fit for tasks is used to avoid manual
cables for ° Inadequate ° Back injuries handling
electrical ABB supervision ° Fall into open holes □ all loads are fastened securely in line with
connections ° Damaged or ° Slipping, triping, falling manufacturers' instructions
defective PPE for ° Impact with falling objects □ when working at heights collective fall protection
of the PASS
electrical works ° Injury to third (scaffolding, nets, railings) is mounted before starting
and yard
° Manual parties works
equipment handling □ ladders are properly selected and used
□ only competent certified scaffolders erect, dismantle
and
inspect scaffolding
□ scaffolding can be neither moved from its place of

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 72 / 162
 installation (block the casters) nor climbed
□ all machinery with moving parts are sufficiently
guarded / interlocked and only competent operators
operate / maintain it in line with the manufacturers'
instructions
□ all openings are covered with unbreakable
material, barricaded and signage is in place
□ all lifting equipment is regularly inspected as per
maintenance
schedules
□ only competent and certified lifting operators operate
lifting
equipment
□ all works, including those carried out by
contractors, are adequately risk assessed,
supervised and executed
□ working at heights is under permit to work system
□ only authorized personnel is present in the lifting area
during
lifting works and the area is barricaded / signed
□ all high-risk activities are controlled by a last minute
/ point-of- work risk assessment before starting works
□ PPE in good condition for the identified tasks is made
available
and all personnel are trained in its use and maintenance
□ fall arrest PPE (lifelines, harness, etc.) are worn when
working
at heights
° Inadequate risk ° Electric shock injuries Ensure that:
Installation of assessment ° Electrocution □ operations are conducted at the lowest possible level
secondary ° Extreme ° Serious injuries □ lifting equipment fit for tasks is used to avoid manual
instruments of weather (fractures, handling
the PASS and conditions amputations) □ all loads are fastened securely in line with
yard ° Portable ° Back injuries manufacturers' instructions
electrical tools ° Fall from heights □ when working at heights collective fall protection
equipment
° Inadequate ° Exposure to UV-radiation (scaffolding,
ABB supervision ° Injury to third nets, railings) is mounted before starting works
° Hot works parties □ ladders are properly selected and used
° Working at □ only competent certified scaffolders erect, dismantle
heights and
° Platforms, inspect scaffolding
ladders and □ scaffolding can be neither moved from its place of
scaffolding installation (block the casters) nor climbed
° Lifting □ all structures, materials, etc. adjacent to welding
operations areas are adequately protected
° Cranes, fork □ works conducted in places exposed to extremes of
lifts, etc. temperature are adequately managed through a
° Damaged or Heat and Cold Weather Working Procedure
defective PPE □ only electrical tools fit for tasks and correctly voltage
for rated are used
mechanical □ ABB's electrical safety standard "The 7 Steps"
works are strictly followed
□ all lifting equipment is regularly inspected as per
maintenance schedules
□ only competent and certified lifting operators operate
lifting
equipment
□ fire fighting equipment is installed near the area where
hot
works are conducted
□ inspection and maintenance of tools are regularly
scheduled
and damaged items are repaired or replaced
□ all works, including those carried out by
contractors, are adequately risk assessed,
supervised and executed
□ working at heights is under permit to work system
□ hot works are under permit to work system and

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 73 / 162
 carried out by competent personnel
□ only authorized personnel is present in the lifting area
during
lifting works and the area is barricaded / signed
□ all high-risk activities are controlled by a last minute /
point-of- work risk assessment before starting works
□ PPE in good condition for the identified tasks is made
available and all personnel are trained in its use and
maintenance
□ fall arrest PPE (lifelines, harness, etc.) are worn
when working at heights
face and respiratory PPE are worn when performing hot
works
° Inadequate risk ° Electric shock injuries Ensure that:
Primary assessment ° Electrocution □ operations are conducted at the lowest possible level
steel/copper ° Extreme ° Serious injuries □ lifting equipment fit for tasks is used to avoid manual
installation weather (fractures, handling
and conditions amputations) □ all loads are fastened securely in line with
connection of ° Portable ° Back injuries manufacturers' instructions
electrical tools ° Fall from heights □ when working at heights collective fall protection
the PASS and
° Inadequate ° Exposure to UV-radiation (scaffolding, nets, railings) is mounted before starting
yard
ABB supervision ° Injury to third works
equipment ° Hot works parties □ ladders are properly selected and used
° Working at □ only competent certified scaffolders erect, dismantle
heights and
° Platforms, inspect scaffolding
ladders and □ scaffolding can be neither moved from its place of
scaffolding installation (block the casters) nor climbed
° Lifting □ all structures, materials, etc. adjacent to welding
operations areas are adequately protected
° Cranes, fork □ works conducted in places exposed to extremes of
lifts, etc. temperature are adequately managed through a
° Damaged or Heat and Cold Weather Working Procedure
defective PPE □ only electrical tools fit for tasks and correctly voltage
for rated are used
mechanical □ ABB's electrical safety standard "The 7 Steps"
works are strictly followed
□ all lifting equipment is regularly inspected as per
maintenance
schedules
□ only competent and certified lifting operators
operate lifting equipment
□ fire fighting equipment is installed near the area where
hot
works are conducted
□ inspection and maintenance of tools are regularly
scheduled
and damaged items are repaired or replaced
□ all works, including those carried out by
contractors, are adequately risk assessed,
supervised and executed
□ working at heights is under permit to work system
□ hot works are under permit to work system and
carried out by competent personnel
□ only authorized personnel are present in the lifting
area during lifting works and the area is barricaded /
signed
□ all high-risk activities are controlled by a last minute /
point-of- work risk assessment before starting works
□ PPE in good condition for the identified tasks is made
available and all personnel are trained in its use and
maintenance
□ fall arrest PPE (lifelines, harness, etc.) are worn
when working at heights
face and respiratory PPE are worn when performing hot
works

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 74 / 162
 ° Inadequate risk ° Electric shock injuries Ensure that:
Installation assessment ° Electrocution □ operations are conducted at the lowest possible level
and ° Extreme ° Serious injuries □ lifting equipment fit for tasks is used to avoid manual
connection of weather (fractures, handling
connecting conditions amputations) □ all loads are fastened securely in line with
cables of the ° Portable ° Back injuries manufacturers' instructions
electrical tools ° Fall from heights □ when working at heights collective fall protection
PASS and
° Inadequate ° Exposure to UV-radiation (scaffolding, nets, railings) is mounted before starting
yard
ABB supervision ° Injury to third works
equipment ° Hot works parties □ ladders are properly selected and used
Modules ° Working at □ only competent certified scaffolders erect, dismantle
heights and
° Platforms, inspect scaffolding
ladders and □ scaffolding can be neither moved from its place of
scaffolding installation (block the casters) nor climbed
° Lifting □ all structures, materials, etc. adjacent to welding
operations areas are adequately protected
° Cranes, fork □ works conducted in places exposed to extremes of
lifts, etc. temperature are adequately managed through a
° Damaged or Heat and Cold Weather Working Procedure
defective PPE □ only electrical tools fit for tasks and correctly voltage
for rated are used
mechanical □ ABB's electrical safety standard "The 7 Steps"
works are strictly followed
□ all lifting equipment is regularly inspected as per
maintenance
schedules
□ only competent and certified lifting operators
operate lifting equipment
□ fire fighting equipment is installed near the area where
hot
works are conducted
□ inspection and maintenance of tools are regularly
scheduled
and damaged items are repaired or replaced
□ all works, including those carried out by
contractors, are adequately risk assessed,
supervised and executed
□ working at heights is under permit to work system
□ hot works are under permit to work system and
carried out by competent personnel
□ only authorized personnel are present in the lifting
area during lifting works and the area is barricaded /
signed
□ all high-risk activities are controlled by a last minute /
point-of- work risk assessment before starting works
□ PPE in good condition for the identified tasks is made
available and all personnel are trained in its use and
maintenance
□ fall arrest PPE (lifelines, harness, etc.) are worn
when working at heights
face and respiratory PPE are worn when performing hot
works
° Inadequate risk ° Electric shock injuries Ensure that:
Installation assessment ° Electrocution □ operations are conducted at the lowest possible level
and ° Extreme ° Serious injuries □ lifting equipment fit for tasks is used to avoid manual
connection of weather (fractures, handling
secondary conditions amputations) □ all loads are fastened securely in line with
earthing of the ° Portable ° Back injuries manufacturers' instructions
electrical tools ° Fall from heights □ when working at heights collective fall protection
PASS and
° Inadequate ° Exposure to UV-radiation (scaffolding,
yard
ABB supervision ° Injury to third nets, railings) is mounted before starting works
equipment ° Hot works parties □ ladders are properly selected and used
Modules ° Working at □ only competent certified scaffolders erect, dismantle
heights and
° Platforms, inspect scaffolding
ladders and □ scaffolding can be neither moved from its place of
scaffolding installation

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 75 / 162
 ° Lifting (block the casters) nor climbed
operations □ all structures, materials, etc. adjacent to welding
° Cranes, fork areas are adequately protected
lifts, etc. □ works conducted in places exposed to extremes of
° Damaged or temperature are adequately managed through a
defective PPE Heat and Cold Weather Working Procedure
for □ only electrical tools fit for tasks and correctly voltage
mechanical rated are used
works □ ABB's electrical safety standard "The 7 Steps"
are strictly followed
□ all lifting equipment is regularly inspected as per
maintenance
schedules
□ only competent and certified lifting operators
operate lifting equipment
□ fire fighting equipment is installed near the area where
hot
works are conducted
□ inspection and maintenance of tools are regularly
scheduled
and damaged items are repaired or replaced
□ all works, including those carried out by
contractors, are adequately risk assessed,
supervised and executed
□ working at heights is under permit to work system
□ hot works are under permit to work system and
carried out by competent personnel
□ only authorized personnel are present in the lifting
area during lifting works and the area is barricaded /
signed
□ all high-risk activities are controlled by a last minute /
point-of- work risk assessment before starting works
□ PPE in good condition for the identified tasks is made
available
and all personnel are trained in its use and maintenance
□ fall arrest PPE (lifelines, harness, etc.) are worn
when working at heights
face and respiratory PPE are worn when performing hot
works
° Inadequate risk ° Serious injuries Ensure that:
Inspection of assessment (fractures, □ operations are conducted at the lowest possible level
cable ° Lone working amputations) □ lifting equipment fit for tasks is used to avoid manual
connection of ° Inadequate ° Back injuries handling
PASS and ABB supervision ° Fall into open holes □ all loads are fastened securely in line with
yard ° Damaged or ° Slipping, tripping, falling manufacturers' instructions
defective PPE for ° Impact with falling objects □ when working at heights collective fall protection
equipment
electrical works ° Injury to third (scaffolding,
Modules
° Manual parties nets, railings) is mounted before starting works
handling □ ladders are properly selected and used
□ only competent certified scaffolders erect, dismantle
and
inspect scaffolding
□ scaffolding can be neither moved from its place of
installation (block the casters) nor climbed
□ all machinery with moving parts are sufficiently
guarded / interlocked and only competent operators
operate / maintain it in line with the manufacturers'
instructions
□ all openings are covered with unbreakable
material, barricaded and signage is in place
□ all lifting equipment is regularly inspected as per
maintenance
schedules
□ only competent and certified lifting operators operate
lifting
equipment
□ all works, including those carried out by
contractors, are adequately risk assessed,

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 76 / 162
 supervised and executed
□ working at heights is under permit to work system
□ only authorized personnel is present in the lifting area
during
lifting works and the area is barricaded / signed
□ all high-risk activities are controlled by a last minute /
point-of- work risk assessment before starting works
□ PPE in good condition for the identified tasks is made
available
and all personnel are trained in its use and maintenance
□ fall arrest PPE (lifelines, harness, etc.) are worn when
working
at heights

4.6.6. MV Switchgear

In order to comply with engineering design and project´s requirements, it is necessary to supply and
install medium voltage electrical panels according to approved single line diagrams in the respective
substation in the scope.

This Method Statement refers to the installation of medium voltage electrical panels, present chapter
sets the construction methodology to perform this work

[Link] Activity

 Movement of personnel using means of transport

 Personnel movements on foot
 Withdrawing materials from the stores
 Removal of packaging prior to installation
 Marking out the panel’s position
 Forming a support surface for offloading the panel
 Moving panels Checking per doc.: “QUALITY CONTROL PLAN – ERECTION”

[Link] Resources

COMPONENTS AND ACCESSORIES

 Medium voltage panel

 Base frames
EQUIPMENT

 Mobile crane
 Truck-mounted crane
 Movement rollers
 Trans pallet
 Reinforced panel movement trolley
 Marking out equipment
 Electric drill
 Electric dowel hole drill
 Material for support surface and movement of panels
 Tackle
 Electric extension cords
 Mechanical tool boxes
 Folding resin ladders

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 77 / 162
[Link] Procedure – Tasks, Hazards, Consequences and Control Measures

Task Hazards Consequences Control Measures

Description

° Inadequate ° Serious injuries Ensure that:

Movement of risk assessment (fractures,  works conducted in places exposed to
personnel & amputations) extremes of temperature are adequately
materials ° Extreme weather ° Back injuries managed through a Heat and Cold Weather
conditions ° Fall into open holes Working Procedure
SAFELY,
° Fall from heights  all works, including those carried out
using means ° Impact with moving
of transport by contractors, are adequately risk
objects assessed, supervised and executed
° Impact with falling
 all high-risk activities are controlled by
objects
a last minute / point-of- work risk
assessment before starting works
° Injury to third parties

° Sharp edges ° Serious injuries Ensure that:

Withdrawing and moving (fractures, □ works conducted in places exposed to extremes of
materials from parts amputations) temperature are adequately managed through a
the stores ° Open holes ° Back injuries Heat and Cold Weather Working Procedure
° Inadequate ° Fall into open holes □ all works, including those carried out by
ABB supervision ° Fall from heights contractors, are adequately risk assessed,
° Working at ° Impact with moving supervised and executed
heights objects □ all high-risk activities are controlled by a last
° Platforms, ° Impact with falling objects minute / point-of- work risk assessment before
ladders and starting works
scaffolding ° Injury to third parties
° Lifting
operations
° Cranes, fork
lifts, etc.
° Damaged or
defective PPE for
mechanical

works

° Sharp edges ° Serious injuries Ensure that:

Removal of and moving (fractures, □ works conducted in places exposed to extremes of
packaging parts amputations) temperature are adequately managed through a
prior to ° Open holes ° Back injuries Heat and Cold Weather Working Procedure
installation ° Inadequate ° Fall into open holes □ all works, including those carried out by
ABB supervision ° Fall from heights contractors, are adequately risk assessed,
° Working at ° Impact with moving supervised and executed
heights objects □ all high-risk activities are controlled by a last
° Platforms, ° Impact with falling objects minute / point-of- work risk assessment before
ladders and ° Injury to third starting works
scaffolding parties
° Lifting
operations
° Cranes, fork
lifts, etc.
° Damaged or
defective PPE
for mechanical
works
° Inadequate risk ° Serious injuries Ensure that:
Marking out assessment (fractures, amputations) □ operations are conducted at the lowest possible level
the panel’s ° Extreme weather ° Exposure to UV- □ lifting equipment fit for tasks is used to avoid manual
position conditions radiation handling
° Open holes □ all loads are fastened securely in line with
° Inadequate ABB manufacturers' instructions
supervision □ when working at heights collective fall protection
° Hot works (scaffolding, nets,

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 78 / 162
 ° Working at railings) is mounted before starting works
heights □ ladders are properly selected and used
° □ only competent certified scaffolders erect, dismantle
Platforms, and inspect
ladders scaffolding
and □ scaffolding can be neither moved from its place of
scaffolding installation (block
° Lifting operations the casters) nor climbed
° Cranes, fork lifts, □ all machinery with moving parts are sufficiently
etc. guarded / interlocked and only competent operators
° Damaged or operate / maintain it in line with the manufacturers'
defective PPE for instructions
mechanical works □ all openings are covered with unbreakable
° Inadequate material, barricaded and signage is in place
emergency □ all lifting equipment is regularly inspected as
response per maintenance schedules
° Manual □ only competent and certified lifting operators operate
handling lifting
equipment
□ all works, including those carried out by
contractors, are adequately risk assessed, supervised
and executed
□ working at heights is under permit to work system
□ only authorized personnel are present in the lifting
area during lifting
works and the area is barricaded / signed
□ all high-risk activities are controlled by a last
minute / point-of-work risk assessment before
starting works
□ PPE in good condition for the identified tasks is
made available and all personnel are trained in its use
and maintenance
fall arrest PPE (lifelines, harness, etc.) are worn when
working at heights
° Inadequate risk ° Serious injuries Ensure that:
Forming a assessment (fractures, amputations) □ lifting equipment fit for tasks is used to avoid manual
support ° Extreme weather ° Exposure to UV- handling
surface for conditions radiation □ all loads are fastened securely in line with
offloading the ° Open holes manufacturers' instructions
panel ° Inadequate ABB □ all manufacturers' handling and installation procedures
supervision for equipment
° Hot works are strictly followed
° Working at □ all openings are covered with unbreakable
heights material, barricaded and signage is in place
° □ all lifting equipment is regularly inspected as
Platforms, per maintenance schedules
ladders □ only competent and certified lifting operators operate
and lifting
scaffolding equipment
° Lifting operations □ all operators have undergone certification training in
° Cranes, fork lifts, safe manual
etc. handling techniques
° Damaged or □ all works, including those carried out by
defective PPE for contractors, are adequately risk assessed, supervised
mechanical works and executed
° Inadequate □ only authorized personnel are present in the lifting
emergency area during lifting
response works and the area is barricaded / signed
° Manual □ all high-risk activities are controlled by a last
handling minute / point-of-work risk assessment before
starting works
□ PPE in good condition for the identified tasks is made
available and all
personnel are trained in its use and maintenance
° Inadequate risk ° Serious injuries Ensure that:
Moving panels assessment (fractures, amputations) □ lifting equipment fit for tasks is used to avoid manual
° Extreme weather ° Exposure to UV- handling
conditions radiation □ all loads are fastened securely in line with

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 79 / 162
 ° Open holes manufacturers' instructions
° Inadequate ABB □ all manufacturers' handling and installation
supervision procedures for equipment are strictly followed
° Hot works □ all openings are covered with unbreakable
° Working at material, barricaded and signage is in place
heights □ all lifting equipment is regularly inspected as per
° maintenance
Platforms, schedules
ladders □ only competent and certified lifting
and operators operate lifting equipment
scaffolding □ all operators have undergone certification training in
° Lifting operations safe manual
° Cranes, fork lifts, handling techniques
etc. □ all works, including those carried out by
° Damaged or contractors, are adequately risk assessed, supervised
defective PPE for and executed
mechanical works □ only authorized personnel are present in the
° Inadequate lifting area during lifting works and the area is
emergency barricaded / signed
response □ all high-risk activities are controlled by a last
° Manual minute / point-of-work risk assessment before
handling starting works
PPE in good condition for the identified tasks is made
available and all personnel are trained in its use and
maintenance

4.6.7. Diesel Generator System

In order to comply with engineering design and project´s requirements, it is necessary to supply and
install medium voltage electrical panels according to approved single line diagrams in the respective
substation in the scope.

This Method Statement refers to the installation of Diesel Generator System, present chapter sets the
construction methodology to perform this work

[Link] Activity

 Movement of personnel using means of transport

 Personnel movements on foot
 Withdrawing materials from the stores
 Removal of packaging prior to installation
 Marking out the equipment’s position
 Forming a support surface for offloading the diesel generators and
complete system
 Moving the diesel generators and complete system
 Checking according to doc.: “QUALITY CONTROL PLAN – ERECTION”

[Link] Resources

COMPONENTS AND ACCESSORIES

 Diesel engine: rated voltage 480V, rating 2080kW prime power

 Radiator + exhaust
 Generator set control panel:

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 80 / 162
  Generator circuit breaker panel
 Generator common center control panel & synchronization equipment
 Fuel handling system & piping
 Fuel Storage tanks-1200 Liter each

EQUIPMENT

 Mobile crane
 Truck-mounted crane
 Movement rollers
 Trans pallet
 Reinforced panel movement trolley
 Marking out equipment
 Electric drill
 Electric dowel hole drill
 Material for support surface and movement of panels
 Tackle

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 81 / 162
[Link] Procedure – Tasks, Hazards, Consequences and Control Measures

Task Hazards Consequences Control Measures

Description

° Inadequate ° Serious injuries Ensure that:

Movement of risk assessment (fractures,  works conducted in places exposed to
personnel & amputations) extremes of temperature are adequately
materials ° Extreme weather ° Back injuries managed through a Heat and Cold Weather
conditions ° Fall into open holes Working Procedure
SAFELY,
° Fall from heights  all works, including those carried out
using means ° Impact with moving
of transport by contractors, are adequately risk
objects assessed, supervised and executed
° Impact with falling
 all high-risk activities are controlled by
objects
a last minute / point-of- work risk
assessment before starting works
° Injury to third parties

° Sharp edges ° Serious injuries Ensure that:

Withdrawing and moving (fractures, □ works conducted in places exposed to extremes of
materials from parts amputations) temperature are adequately managed through a
the stores ° Open holes ° Back injuries Heat and Cold Weather Working Procedure
° Inadequate ° Fall into open holes □ all works, including those carried out by
ABB supervision ° Fall from heights contractors, are adequately risk assessed,
° Working at ° Impact with moving supervised and executed
heights objects □ all high-risk activities are controlled by a last
° Platforms, ° Impact with falling objects minute / point-of- work risk assessment before
ladders and starting works
scaffolding ° Injury to third parties
° Lifting
operations
° Cranes, fork
lifts, etc.
° Damaged or
defective PPE for
mechanical

works

° Sharp edges ° Serious injuries Ensure that:

Removal of and moving (fractures, □ works conducted in places exposed to extremes of
packaging parts amputations) temperature are adequately managed through a
prior to ° Open holes ° Back injuries Heat and Cold Weather Working Procedure
installation ° Inadequate ° Fall into open holes □ all works, including those carried out by
ABB supervision ° Fall from heights contractors, are adequately risk assessed,
° Working at ° Impact with moving supervised and executed
heights objects □ all high-risk activities are controlled by a last
° Platforms, ° Impact with falling objects minute / point-of- work risk assessment before
ladders and ° Injury to third starting works
scaffolding parties
° Lifting
operations
° Cranes, fork
lifts, etc.
° Damaged or
defective PPE
for mechanical
works
° Inadequate risk ° Serious injuries Ensure that:
Marking out assessment (fractures, amputations) □ operations are conducted at the lowest possible level
the Diesel ° Extreme weather ° Exposure to UV- □ lifting equipment fit for tasks is used to avoid manual
conditions radiation handling

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 82 / 162
 Generator´s ° Open holes □ all loads are fastened securely in line with
position ° Inadequate ABB manufacturers' instructions
supervision □ when working at heights collective fall protection
° Hot works (scaffolding, nets, railings) is mounted before
° Working at starting works
heights □ ladders are properly selected and used
° □ only competent certified scaffolders erect, dismantle
Platforms, and inspect
ladders scaffolding
and □ scaffolding can be neither moved from its place of
scaffolding installation (block the casters) nor climbed
° Lifting operations □ all machinery with moving parts are sufficiently
° Cranes, fork lifts, guarded / interlocked and only competent operators
etc. operate / maintain it in line with the manufacturers'
° Damaged or instructions
defective PPE for □ all openings are covered with unbreakable
mechanical works material, barricaded and signage is in place
° Inadequate □ all lifting equipment is regularly inspected as per
emergency maintenance
response schedules
° Manual □ only competent and certified lifting operators operate
handling lifting
equipment
□ all works, including those carried out by
contractors, are adequately risk assessed, supervised
and executed
□ working at heights is under permit to work system
□ only authorized personnel is present in the lifting area
during lifting
works and the area is barricaded / signed
□ all high-risk activities are controlled by a last
minute / point-of-work risk assessment before
starting works
□ PPE in good condition for the identified tasks is made
available and all
personnel are trained in its use and maintenance
fall arrest PPE (lifelines, harness, etc.) are worn when
working at heights
° Inadequate risk ° Serious injuries Ensure that:
Forming a assessment (fractures, amputations) □ lifting equipment fit for tasks is used to avoid manual
support ° Extreme weather ° Exposure to UV- handling
surface for conditions radiation □ all loads are fastened securely in line with
offloading the ° Open holes manufacturers' instructions
Diesel ° Inadequate ABB □ all manufacturers' handling and installation procedures
supervision for equipment
Generator´s
° Hot works are strictly followed
° Working at □ all openings are covered with unbreakable
heights material, barricaded and signage is in place
° □ all lifting equipment is regularly inspected as per
Platforms, maintenance
ladders schedules
and □ only competent and certified lifting operators operate
scaffolding lifting
° Lifting operations equipment
° Cranes, fork lifts, □ all operators have undergone certification
etc. training in safe manual handling techniques
° Damaged or □ all works, including those carried out by
defective PPE for contractors, are adequately risk assessed, supervised
mechanical works and executed
° Inadequate □ only authorized personnel is present in the lifting area
emergency during lifting
response works and the area is barricaded / signed
° Manual □ all high-risk activities are controlled by a last
handling minute / point-of-work risk assessment before
starting works
□ PPE in good condition for the identified tasks is made
available and all
personnel are trained in its use and maintenance

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 83 / 162
 ° Inadequate risk ° Serious injuries Ensure that:
Moving Diesel assessment (fractures, amputations) □ lifting equipment fit for tasks is used to avoid manual
Generator´s ° Extreme weather ° Exposure to UV- handling
conditions radiation □ all loads are fastened securely in line with
° Open holes manufacturers' instructions
° Inadequate ABB □ all manufacturers' handling and installation procedures
supervision for equipment
° Hot works are strictly followed
° Working at □ all openings are covered with unbreakable material,
heights barricaded and signage is in place
° □ all lifting equipment is regularly inspected as
Platforms, per maintenance schedules
ladders □ only competent and certified lifting operators operate
and lifting
scaffolding equipment
° Lifting operations □ all operators have undergone certification training in
° Cranes, fork lifts, safe manual handling techniques
etc. □ all works, including those carried out by contractors,
° Damaged or are adequately risk assessed, supervised and
defective PPE for executed
mechanical works □ only authorized personnel are present in the lifting area
° Inadequate during lifting works and the area is barricaded / signed
emergency □ all high-risk activities are controlled by a last minute /
response point-of-work risk assessment before starting works
° Manual □ PPE in good condi on for the iden fied tasks is made
handling available and all personnel are trained in its use and
maintenance
Prior to start installation, Site Engineer (Electrical) should
Installation ensure that approved shop drawings related to the
Diesel installation area are referred and that required materials
Generator´s are available at site as per approved material submittals.

Site Engineer (Electrical) has to ensure that all the

materials are received at site as per approved material
submittal and verify the ratings.

The name plate will be checked against equipment

data sheet to confirm conformity with the
approval.

Material Inspection Request should be raised for

material verification upon delivery at site.

Ensure all civil works are completed for the area

including floor paint to carry out the installation, and
clearance is obtained from respective authorities to
proceed further installation of DG set.

Installation procedures are to be followed as per

manufacturers recommendations.

Installation works shall be carried out only with

respect to approved shop drawings of latest
revision.

Diesel Generator Set will be off loaded to the place

nearest to the installation and protected properly
from dust & environment, etc. Prior to installation,
the foundation will be checked for cleanliness and
level.

Site Engineer must ensure the orientation of DG set as

per approved shop drawing Exhaust duct & fuel oil pipe
installation shall comply with the relevant clauses of
specifications and as per manufacturer
recommendation.

Ensure that the installation of Diesel Generator Set is

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 84 / 162
 carried out in accordance with manufacturer’s and
authority’s installation recommendations, requirement
of applicable standards and in accordance with
recognized industrial practices and specified in project
specification to ensure that installation complies with
requirements.

Alternator neutral terminal & Body shall be

connected with external earth as per approved shop
drawing.

Alternator control panel shall be connected as

per approved shop drawing and manufacturer
recommendations

Cable connections between alternator, control panel and

Emergency Main Distribution Board shall be done as per
approved shop drawing.

From the Emergency Main Distribution Board to

other sub emergency panels, Power Distribution
work shall be done as per approved shop drawing

Installation of muffler, fuel supply system, exhaust

ducts, circuit breaker installation connections to BMS
and control wires shall be carried out as per approved
specifications.

Pre & Post installation start up and commissioning at

site using available site load shall be performed in
coordination with the manufacturer’s local dealer in
the presence of consultant representative as
appropriate. Detailed procedure shall be submitted for
Testing pre-commissioning and commissioning checks
for consultant’s approval prior to commissioning of
genset. Applicable operating instruction, service
manuals, recommended spares shall be submitted in
O&M manual.
Required power and control termination shall be carried
out as per approved drawings.

DG Set Earthing shall be done as per authority

Regulation, specification and approved drawings.

After inspection of DG Set proper care will be taken to

protect the unit from dust by suitable covering, and shall
further be released for the Testing work.

4.6.8. LV Switchgear and LV Panels AC/DC

In order to comply with project´s requirements and engineering design, it is necessary to supply and
install Primary LV panel.

The present chapter sets the construction methodology to perform this work.

[Link] Activity

 Movement of personnel using means of transport

 Personnel movements on foot
 Pick-up of materials from stores.
 Removal of packaging prior to installation

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 85 / 162
  Marking out the panel's position
 Unloading of panel onto prepared foundation
 Check according to doc.: "QUALITY CONTROL PLAN – ERECTION"

[Link] Resources

COMPONENTS AND ACCESSORIES

 AC/DC switchgear
 Primary LV panel, POWER CENTER
EQUIPMENTS
 Forklift truck
 Truck-mounted crane
 Movement rollers
 Pallet truck
 Reinforced panel movement trolley
 Marking out equipment
 Power drill
 Heavy duty power drill
 Material for support surface and movement of panels
 Crowbars
 Power extension leads
 Mechanic's tool boxes
 Electrician's tool boxes
 Folding resin ladders

[Link] Procedure – Tasks, Hazards, Consequences and Control Measures

Task Hazards Consequences Control Measures

Description

° Inadequate ° Serious injuries Ensure that:

Movement of risk assessment (fractures,  works conducted in places exposed to
personnel & amputations) extremes of temperature are adequately
materials ° Extreme weather ° Back injuries managed through a Heat and Cold Weather
conditions ° Fall into open holes Working Procedure
SAFELY,
° Fall from heights  all works, including those carried out
using means ° Impact with moving
of transport by contractors, are adequately risk
objects assessed, supervised and executed
° Impact with falling
 all high-risk activities are controlled by
objects
a last minute / point-of- work risk
assessment before starting works
° Injury to third parties

SAFELY ° Inadequate risk ° Serious injuries Ensure that:

assessment (fractures, amputations) □ works conducted in places exposed to extremes of
Personnel ° Extreme ° Exposure to UV- temperature are adequately managed through a
movement on weather radiation Heat and Cold Weather Working Procedure
foot conditions □ all works, including those carried out by
contractors, are adequately risk assessed, supervised
and executed

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 86 / 162
 all high-risk activities are controlled by a last minute /
point-of-work risk assessment before starting works
° Sharp edges ° Serious injuries Ensure that:
Withdrawing and moving (fractures, □ works conducted in places exposed to extremes of
materials from parts amputations) temperature are adequately managed through a
the stores ° Open holes ° Back injuries Heat and Cold Weather Working Procedure
° Inadequate ° Fall into open holes □ all works, including those carried out by
ABB supervision ° Fall from heights contractors, are adequately risk assessed,
° Working at ° Impact with moving supervised and executed
heights objects □ all high-risk activities are controlled by a last
° Platforms, ° Impact with falling objects minute / point-of- work risk assessment before
ladders and starting works
scaffolding ° Injury to third parties
° Lifting
operations
° Cranes, fork
lifts, etc.
° Damaged or
defective PPE for
mechanical

works

° Sharp edges ° Serious injuries Ensure that:

Removal of and moving (fractures, □ works conducted in places exposed to extremes of
packaging parts amputations) temperature are adequately managed through a
prior to ° Open holes ° Back injuries Heat and Cold Weather Working Procedure
installation ° Inadequate ° Fall into open holes □ all works, including those carried out by
ABB supervision ° Fall from heights contractors, are adequately risk assessed,
° Working at ° Impact with moving supervised and executed
heights objects □ all high-risk activities are controlled by a last
° Platforms, ° Impact with falling objects minute / point-of- work risk assessment before
ladders and ° Injury to third starting works
scaffolding parties
° Lifting
operations
° Cranes, fork
lifts, etc.
° Damaged or
defective PPE
for mechanical
works
° Inadequate risk ° Serious injuries Ensure that:
Identification assessment (fractures, amputations) □ operations are conducted at the lowest possible level
and marking ° Lone working ° Back injuries □ lifting equipment fit for tasks is used to avoid manual
of MV cables ° Inadequate ABB ° Fall into open holes handling
supervision ° Fall from heights □ all loads are fastened securely in line with
° Damaged or ° Impact with falling objects manufacturers' instructions
defective PPE ° Exposure to UV-radiation □ when working at heights collective fall protection
for electrical ° Injury to third (scaffolding, nets, railings) is mounted before
works parties starting works
° Manual □ ladders are properly selected and used
handling □ only competent certified scaffolders erect, dismantle
and inspect
scaffolding
□ scaffolding can be neither moved from its place of
installation (block
the casters) nor climbed
□ all machinery with moving parts are sufficiently
guarded / interlocked and only competent operators
operate / maintain it in line with the manufacturers'
instructions
□ all openings are covered with unbreakable
material, barricaded and signage is in place
□ all lifting equipment is regularly inspected as per
maintenance
schedules
□ only competent and certified lifting operators operate

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 87 / 162
 lifting
equipment
□ all works, including those carried out by
contractors, are adequately risk assessed, supervised
and executed
□ working at heights is under permit to work system
□ only authorized personnel is present in the lifting area
during lifting
works and the area is barricaded / signed
□ all high-risk activities are controlled by a last
minute / point-of-work risk assessment before
starting works
□ PPE in good condition for the identified tasks is made
available and all
personnel are trained in its use and maintenance
fall arrest PPE (lifelines, harness, etc.) are worn when
working at heights

4.6.9. Power and Distribution Transformers

In order to comply with project´s requirements and engineering design, it is necessary to supply,
installing, unloading and outfitting the power and distribution Transformers.

The present chapter sets the construction methodology to perform this work

[Link] ACTIVITY

 Movement of personnel & materials SAFELY, using means of transport

 SAFELY Personnel movement on foot
 Withdrawing materials from the stores
 Removal of packaging prior to installation
 Inspection of foundation
 Unloading and positioning of transformer on concrete foundation
 Installing of transformer outfitting components, positioning and
assembly of components
 Connecting of pre-cabled secondary cables of equipment
 Installing and connecting of secondary earthing system
 Positioning of conservators and connecting of tubes for oil treatment.
 Preparation, installation and connection of power / generator line for
transformer oil treatment machine
 Treatment of transformer oil.
 Pre-commissioning tests from equipment to local transformer board
 Checks, tests and inspections according to doc. "QUALITY CONTROL PLAN
ERECTION"

[Link] Resources

COMPONENTS AND ACCESSORIES

 Transformer tank

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 88 / 162
  Components for outfitting
 Conservators
 Oil treatment plant
 Generator for oil treatment plant

EQUIPMENT

 Forklift truck
 Crane
 Truck-mounted crane
 15m-high mobile platform
 Torque wrenches
 Mechanic's tool box
 Electrician's tool box

[Link] Procedure – Tasks, Hazards, Consequences and Control Measures

Task Description Hazards Consequences Control Measures

° Inadequate risk ° Serious injuries Ensure that:

Movement of assessment (fractures,  works conducted in places
personnel & amputations) exposed to extremes of
materials SAFELY, ° Extreme weather ° Back injuries temperature are adequately
conditions ° Fall into open holes managed through a Heat and Cold
using means of
° Fall from heights Weather Working Procedure
transport ° Impact with moving  all works, including those
objects carried out by contractors, are
° Impact with falling
adequately risk assessed,
objects
supervised and executed
 all high-risk activities are
° Injury to third parties
controlled by a last minute /
point-of- work risk
assessment before starting
works
SAFELY ° Inadequate risk ° Serious injuries Ensure that:
assessment (fractures, □ works conducted in places exposed to
Personnel ° Extreme weather amputations) extremes of temperature are adequately
movement on foot conditions ° Exposure to UV- managed through a Heat and Cold Weather
radiation Working Procedure
□ all works, including those carried out by
contractors, are adequately risk assessed,
supervised and executed
all high-risk activities are controlled by a last
minute / point-of-work risk assessment before
starting works
° Sharp edges and ° Serious injuries Ensure that:
Withdrawing moving parts (fractures, □ works conducted in places exposed to
materials from the ° Open holes amputations) extremes of temperature are adequately
stores ° Inadequate ABB ° Back injuries managed through a Heat and Cold Weather
supervision ° Fall into open holes Working Procedure
° Working at ° Fall from heights □ all works, including those carried out
heights ° Impact with moving by contractors, are adequately risk
° Platforms, objects assessed, supervised and executed
ladders and ° Impact with falling □ all high-risk activities are controlled
scaffolding objects by a last minute / point-of- work risk
° Lifting operations assessment before starting works
° Cranes, fork lifts, etc.

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 89 / 162
 ° Damaged or defective
PPE for mechanical ° Injury to third parties

works

° Sharp edges and ° Serious injuries Ensure that:

Removal of moving parts (fractures, □ works conducted in places exposed to
packaging prior to ° Open holes amputations) extremes of temperature are adequately
installation ° Inadequate ABB ° Back injuries managed through a Heat and Cold Weather
supervision ° Fall into open holes Working Procedure
° Working at ° Fall from heights □ all works, including those carried out
heights ° Impact with moving by contractors, are adequately risk
° Platforms, objects assessed, supervised and executed
ladders and ° Impact with falling □ all high-risk activities are controlled
scaffolding objects by a last minute / point-of- work risk
° Lifting operations ° Injury to third assessment before starting works
° Cranes, fork lifts, etc. parties
° Damaged or
defective PPE for
mechanical works
° Inadequate risk ° Serious injuries Ensure that:
Inspection of assessment (fractures, □ operations are conducted at the lowest
foundation ° Extreme weather amputations) possible level
conditions ° Back injuries □ lifting equipment fit for tasks is used to avoid
° Portable electrical ° Fall into open holes manual handling
tools ° Impact with falling □ all loads are fastened securely in
° objects line with manufacturers' instructions
Inadequate ° Injury to third □ when working at heights collective fall
ABB parties protection (scaffolding,
supervision nets, railings) is mounted before starting works
° Working at heights □ ladders are properly selected and used
° Platforms, □ only competent certified scaffolders erect,
ladders and dismantle and inspect
scaffolding scaffolding
° Lifting operations □ scaffolding can be neither moved from
° Cranes, fork lifts, etc. its place of installation (block the casters)
° Damaged or nor climbed
defective PPE for □ all machinery with moving parts are
mechanical works sufficiently guarded / interlocked and only
° Manual handling competent operators operate / maintain it in
line with the manufacturers' instructions
□ all openings are covered with unbreakable
material, barricaded and signage is in place
□ all lifting equipment is regularly inspected as
per maintenance
schedules
□ only competent and certified lifting operators
operate lifting
equipment
□ all works, including those carried
out by contractors, are adequately
risk assessed, supervised and
executed
□ working at heights is under permit to work
system
□ only authorized personnel are present in the
lifting area during
lifting works and the area is barricaded / signed
□ all high-risk activities are controlled by a
last minute / point-of- work risk assessment
before starting works
□ PPE in good condition for the identified tasks
is made available
and all personnel are trained in its use and
maintenance
fall arrest PPE (lifelines, harness, etc.) are worn
when working at heights

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 90 / 162
 ° Inadequate risk ° Serious injuries Ensure that:
Unloading and assessment (fractures, □ lifting equipment fit for tasks is used to avoid
positioning of ° Extreme weather amputations) manual handling
transformer on conditions ° Back injuries □ all loads are fastened securely in
concrete foundation ° Portable electrical ° Fall into open holes line with manufacturers' instructions
tools ° Impact with falling □ all manufacturers' handling and
° objects installation procedures for equipment
Inadequate ° Injury to third are strictly followed
ABB parties □ all openings are covered with unbreakable
supervision material, barricaded and signage is in place
° Working at heights □ all lifting equipment is regularly inspected as
° Platforms, per maintenance
ladders and schedules
scaffolding □ only competent and certified lifting
° Lifting operations operators operate lifting equipment
° Cranes, fork lifts, etc. □ all operators have undergone certification
° Damaged or training in safe manual
defective PPE for handling techniques
mechanical works □ all works, including those carried
° Manual handling out by contractors, are adequately
risk assessed, supervised and
executed
□ only authorized personnel is present in
the lifting area during lifting works and
the area is barricaded / signed
□ all high-risk activities are controlled by a
last minute / point-of- work risk assessment
before starting works
PPE in good condition for the identified tasks is
made available and all personnel are trained in
its use and maintenance
° Inadequate risk ° Serious injuries Ensure that:
Installing of assessment (fractures, □ operations are conducted at the lowest
transformer ° Extreme weather amputations) possible level
outfitting conditions ° Back injuries □ lifting equipment fit for tasks is used to avoid
components, ° Portable electrical ° Fall into open holes manual handling
positioning and tools ° Impact with falling □ all loads are fastened securely in
° objects line with manufacturers' instructions
assembly of
Inadequate ° Injury to third □ when working at heights collective fall
components
ABB parties protection (scaffolding,
supervision nets, railings) is mounted before starting works
° Working at heights □ ladders are properly selected and used
° Platforms, □ only competent certified scaffolders erect,
ladders and dismantle and inspect scaffolding
scaffolding □ scaffolding can be neither moved from its
° Lifting operations place of installation
° Cranes, fork lifts, etc. (block the casters) nor climbed
° Damaged or □ all structures, materials, etc. adjacent
defective PPE for to welding areas are adequately
mechanical works protected
° Manual handling □ works conducted in places exposed to
extremes of temperature are adequately
managed through a Heat and Cold Weather
Working Procedure
□ only electrical tools fit for tasks and
correctly voltage rated are used
□ ABB's electrical safety standard "The 7 Steps"
are strictly followed
□ all lifting equipment is regularly
inspected as per maintenance schedules
□ only competent and certified lifting operators
operate lifting
equipment
□ fire fighting equipment is installed near the
area where hot works
are conducted
□ inspection and maintenance of tools are
regularly scheduled and damaged items are

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 91 / 162
 repaired or replaced
□ all works, including those carried
out by contractors, are adequately
risk assessed, supervised and
executed
□ working at heights is under permit to work
system
□ hot works are under permit to work
system and carried out by competent
personnel
□ only authorized personnel are present in the
lifting area during
lifting works and the area is barricaded / signed
□ all high-risk activities are controlled by a
last minute / point-of- work risk assessment
before starting works
□ PPE in good condition for the identified tasks
is made available
and all personnel are trained in its use and
maintenance
□ fall arrest PPE (lifelines, harness, etc.) are
worn when working at heights
face and respiratory PPE are worn when
performing hot works
° Inadequate risk ° Serious injuries Ensure that:
Connecting of pre- assessment (fractures, □ operations are conducted at the lowest
cabled secondary ° Extreme weather amputations) possible level
cables of equipment conditions ° Back injuries □ lifting equipment fit for tasks is used to avoid
° Portable electrical ° Fall into open holes manual handling
tools ° Impact with falling □ all loads are fastened securely in
° objects line with manufacturers' instructions
Inadequate ° Injury to third □ when working at heights collective fall
ABB parties protection (scaffolding, nets, railings) is
supervision mounted before starting works
° Working at heights □ ladders are properly selected and used
° Platforms, □ only competent certified scaffolders erect,
ladders and dismantle and inspect
scaffolding scaffolding
° Lifting operations □ scaffolding can be neither moved from
° Cranes, fork lifts, etc. its place of installation (block the casters)
° Damaged or nor climbed
defective PPE for □ all structures, materials, etc. adjacent
mechanical works to welding areas are adequately
° Manual handling protected
□ works conducted in places exposed to
extremes of temperature are adequately
managed through a Heat and Cold Weather
Working Procedure
□ only electrical tools fit for tasks and
correctly voltage rated are used
□ ABB's electrical safety standard "The 7 Steps"
are strictly followed
□ all lifting equipment is regularly inspected as
per maintenance
schedules
□ only competent and certified lifting
operators operate lifting equipment
□ fire fighting equipment is installed near the
area where hot works
are conducted
□ inspection and maintenance of tools are
regularly scheduled and
damaged items are repaired or replaced
□ all works, including those carried
out by contractors, are adequately
risk assessed, supervised and
executed
□ working at heights is under permit to work

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 92 / 162
 system
□ hot works are under permit to work
system and carried out by competent
personnel
□ only authorized personnel are present
in the lifting area during lifting works and
the area is barricaded / signed
□ all high-risk activities are controlled by a
last minute / point-of- work risk assessment
before starting works
□ PPE in good condition for the identified
tasks is made available and all personnel
are trained in its use and maintenance
□ fall arrest PPE (lifelines, harness, etc.) are
worn when working at heights
face and respiratory PPE are worn when
performing hot works
° Inadequate risk ° Electric shock injuries Ensure that:
Installing and assessment ° Electrocution □ operations are conducted at the lowest
connecting of ° Extreme weather ° Serious injuries possible level
secondary earthing conditions (fractures, □ lifting equipment fit for tasks is used to avoid
system ° Portable electrical amputations) manual handling
tools ° Back injuries □ all loads are fastened securely in
° ° Fall from heights line with manufacturers' instructions
Inadequate ° Exposure to UV- □ when working at heights collective fall
ABB radiation protection (scaffolding, nets, railings) is
supervision ° Injury to third mounted before starting works
° Hot works parties □ ladders are properly selected and used
° Working at heights □ only competent certified scaffolders erect,
° Platforms, dismantle and inspect
ladders and scaffolding
scaffolding □ scaffolding can be neither moved from its
° Lifting operations place of installation
° Cranes, fork lifts, etc. (block the casters) nor climbed
° Damaged or □ all structures, materials, etc. adjacent
defective PPE for to welding areas are adequately
mechanical works protected
□ works conducted in places exposed to
extremes of temperature are adequately
managed through a Heat and Cold Weather
Working Procedure
□ only electrical tools fit for tasks and
correctly voltage rated are used
□ ABB's electrical safety standard "The 7 Steps"
are strictly followed
□ all lifting equipment is regularly inspected as
per maintenance
schedules
□ only competent and certified lifting
operators operate lifting equipment
□ fire fighting equipment is installed near the
area where hot works
are conducted
□ inspection and maintenance of tools are
regularly scheduled and
damaged items are repaired or replaced
□ all works, including those carried
out by contractors, are adequately
risk assessed, supervised and
executed
□ working at heights is under permit to work
system
□ hot works are under permit to work
system and carried out by competent
personnel
□ only authorized personnel are present
in the lifting area during lifting works and
the area is barricaded / signed

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 93 / 162
 □ all high-risk activities are controlled by a
last minute / point-of- work risk assessment
before starting works
□ PPE in good condition for the identified tasks
is made available
and all personnel are trained in its use and
maintenance
□ fall arrest PPE (lifelines, harness, etc.) are
worn when working at heights
face and respiratory PPE are worn when
performing hot works
Positioning of ° Inadequate risk ° Serious injuries Ensure that:
conservators and assessment (fractures, □ operations are conducted at the lowest
connecting of ° Extreme weather amputations) possible level
tubes for oil conditions ° Back injuries □ lifting equipment fit for tasks is used to avoid
treatment (VALID ° Portable electrical ° Fall into open holes manual handling
FOR POWER tools ° Impact with falling □ all loads are fastened securely in
TRANSFORMERS). ° objects line with manufacturers' instructions
Inadequate ° Injury to third □ when working at heights collective fall
ABB parties protection (scaffolding,
supervision nets, railings) is mounted before starting works
° Working at heights □ ladders are properly selected and used
° Platforms, □ only competent certified scaffolders erect,
ladders and dismantle and inspect
scaffolding scaffolding
° Lifting operations □ scaffolding can be neither moved from its
° Cranes, fork lifts, etc. place of installation
° Damaged or (block the casters) nor climbed
defective PPE for □ all machinery with moving parts are
mechanical works sufficiently guarded / interlocked and only
° Manual handling competent operators operate / maintain it in
line with the manufacturers' instructions
□ all openings are covered with unbreakable
material, barricaded and signage is in place
□ all lifting equipment is regularly
inspected as per maintenance schedules
□ only competent and certified lifting operators
operate lifting
equipment
□ all works, including those carried
out by contractors, are adequately
risk assessed, supervised and
executed
□ working at heights is under permit to work
system
□ only authorized personnel are present in the
lifting area during
lifting works and the area is barricaded / signed
□ all high-risk activities are controlled by a
last minute / point-of- work risk assessment
before starting works
□ PPE in good condition for the identified tasks
is made available and all personnel are trained
in its use and maintenance fall arrest PPE
(lifelines, harness, etc.) are worn when
working at heights
Preparation, ° Inadequate risk ° Serious injuries Ensure that:
installation and assessment (fractures, □ lifting equipment fit for tasks is used to avoid
connection of ° Extreme weather amputations) manual handling
power / generator conditions ° Back injuries □ all loads are fastened securely in
line for ° Portable electrical ° Fall into open holes line with manufacturers' instructions
transformer oil tools ° Impact with falling □ all manufacturers' handling and installation
treatment ° objects procedures for equipment is strictly followed
machine Inadequate □ all openings are covered with unbreakable
ABB ° Injury to third material, barricaded and signage is in place
supervision parties □ all lifting equipment is regularly inspected as
° Working at heights per maintenance
° Platforms, schedules

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 94 / 162
 ladders and □ only competent and certified lifting operators
(VALID FOR scaffolding operate lifting
POWER ° Lifting operations equipment
TRANSFORMERS) ° Cranes, fork lifts, etc. □ all operators have undergone certification
° Damaged or training in safe manual handling techniques
defective PPE for □ all works, including those carried
mechanical works out by contractors, are adequately
° Manual handling risk assessed, supervised and
executed
□ only authorized personnel are present
in the lifting area during lifting works and
the area is barricaded / signed
□ all high-risk activities are controlled by a
last minute / point-of- work risk assessment
before starting works
□ PPE in good condition for the identified tasks
is made available
and all personnel are trained in its use and
maintenance
° Inadequate risk ° Serious injuries Ensure that:
Treatment of assessment (fractures, □ operations are conducted at the lowest
transformer oil ° Extreme weather amputations) possible level
(VALID FOR conditions ° Back injuries □ lifting equipment fit for tasks is used to avoid
POWER ° Portable electrical ° Fall into open holes manual handling
TRANSFORMERS). tools ° Impact with falling □ hazardous substances, whenever possible, are
° objects substituted by less
Inadequate ° Injury to third / non-hazardous ones
ABB parties □ all loads are fastened securely in
supervision line with manufacturers' instructions
° Working at heights □ when working at heights collective fall
° Platforms, protection (scaffolding,
ladders and nets, railings) is mounted before starting works
scaffolding □ ladders are properly selected and used
° Lifting operations □ only competent certified scaffolders erect,
° Cranes, fork lifts, etc. dismantle and inspect scaffolding
° Damaged or □ scaffolding can be neither moved from its
defective PPE for place of installation
mechanical works (block the casters) nor climbed
° Manual handling □ all manufacturers' handling and installation
procedures for
equipment is strictly followed
□ all structures, materials, etc. adjacent
to welding areas are adequately
protected
□ works conducted in places exposed to
extremes of temperature are adequately
managed through a Heat and Cold Weather
Working Procedure
□ all openings are covered with unbreakable
material, barricaded and signage is in place
□ all lifting equipment is regularly inspected as
per maintenance
schedules
□ only competent and certified lifting operators
operate lifting
equipment
□ competent personnel are engaged
in handling dangerous substances and
a full chemical assessment is made
□ an eye wash station and spillage containment
equipment is
installed
□ fire fighting equipment is installed near the
area where hot works
are conducted
□ all operators have undergone certification
training in safe manual handling techniques
□ all local emergency contact numbers are

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 95 / 162
 clearly displayed and competent first
aiders are in place
□ all works, including those carried
out by contractors, are adequately
risk assessed, supervised and
executed
□ working at heights is under permit to work
system
□ emergency response equipment e.g.
spill kits, fire fighting, medical emergency
equipment function properly and
defective items are replaced immediately
□ hot works are under permit to work
system and carried out by competent
personnel
□ only authorized personnel are present in the
lifting area during
lifting works and the area is barricaded / signed
□ all high-risk activities are controlled by a
last minute / point-of- work risk assessment
before starting works
□ PPE in good condition for the identified
tasks is made available and all personnel
are trained in its use and maintenance
□ fall arrest PPE (lifelines, harness, etc.) are
worn when working at heights
face and respiratory PPE are worn when
performing hot works

4.6.10. AC/DC Panel - Rectifier - Batteries

In order to comply with project´s requirements and engineering design, it is necessary to supply,
installing, unloading and outfitting the to install the panels AC/DC - rectifier - batteries

The chapter sets the construction methodology to perform this work

[Link] Activity

 Movement of personnel using means of transport

 Personnel movements on foot
 Pick-up of materials from stores.
 Removal of packaging prior to installation
 Marking out the panel's position
 Unloading of panel onto prepared foundation
 Check according to doc.: "QUALITY CONTROL PLAN – ERECTION"

[Link] Resources

COMPONENTS AND ACCESSORIES

 AC/DC panel Rectifier/Converter - batteries

EQUIPMENT

 Equipment Forklift truck

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 96 / 162
  Truck-mounted crane Movement rollers Pallet truck
 Reinforced panel movement trolley Marking out equipment
 Power drill
 Heavy duty power drill
 Material for support surface and movement of panels Crowbars
 Power extension leads Mechanic's tool boxes Electrician's tool boxes Folding resin
ladders.

[Link] Procedure – Tasks, Hazards, Consequences and Control Measures

Task Hazards Consequences Control Measures

Description

° Inadequate ° Serious injuries Ensure that:

Movement of risk assessment (fractures,  works conducted in places exposed to
personnel & amputations) extremes of temperature are adequately
materials ° Extreme weather ° Back injuries managed through a Heat and Cold
conditions ° Fall into open holes Weather Working Procedure
SAFELY,
° Fall from heights  all works, including those carried out
using means ° Impact with moving
of transport by contractors, are adequately risk
objects assessed, supervised and executed
° Impact with falling
 all high-risk activities are controlled
objects
by a last minute / point-of- work risk
assessment before starting works
° Injury to third parties

SAFELY ° Inadequate risk ° Serious injuries Ensure that:

assessment (fractures, amputations) □ works conducted in places exposed to extremes
Personnel ° Extreme ° Exposure to UV- of temperature are adequately managed through a
movement on weather radiation Heat and Cold Weather Working Procedure
foot conditions □ all works, including those carried out by
contractors, are adequately risk assessed,
supervised and executed
all high-risk activities are controlled by a last minute /
point-of-work risk assessment before starting works
° Sharp edges ° Serious injuries Ensure that:
Withdrawing and moving (fractures, □ works conducted in places exposed to extremes
materials from parts amputations) of temperature are adequately managed through a
the stores ° Open holes ° Back injuries Heat and Cold Weather Working Procedure
° Inadequate ° Fall into open holes □ all works, including those carried out by
ABB supervision ° Fall from heights contractors, are adequately risk assessed,
° Working at ° Impact with moving objects supervised and executed
heights ° Impact with falling objects □ all high-risk activities are controlled by a last
° Platforms, minute / point-of- work risk assessment before
ladders and ° Injury to third parties starting works
scaffolding
° Lifting
operations
° Cranes, fork
lifts, etc.
° Damaged or
defective PPE for
mechanical

works

° Sharp edges ° Serious injuries Ensure that:

Removal of and moving (fractures, □ works conducted in places exposed to extremes
packaging parts amputations) of temperature are adequately managed through a
° Open holes ° Back injuries Heat and Cold Weather Working Procedure

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 97 / 162
 prior to ° Inadequate ° Fall into open holes □ all works, including those carried out by
installation ABB supervision ° Fall from heights contractors, are adequately risk assessed,
° Working at ° Impact with moving objects supervised and executed
heights ° Impact with falling objects □ all high-risk activities are controlled by a last
° Platforms, ° Injury to third minute / point-of- work risk assessment before
ladders and parties starting works
scaffolding
° Lifting
operations
° Cranes, fork
lifts, etc.
° Damaged or
defective PPE
for mechanical
works
° Inadequate risk ° Serious Ensure that:
Marking out assessment injuries □ operations are conducted at the lowest possible level
the panel's ° Extreme weather (fractures, □ lifting equipment fit for tasks is used to avoid manual
position conditions amputations) handling
° Portable ° Back injuries □ all loads are fastened securely in line
electrical ° Fall into open holes with manufacturers' instructions
tools ° Impact with falling objects □ when working at heights collective fall
° ° Injury to third protection (scaffolding, nets, railings) is mounted
Inadequate parties before starting works
ABB □ ladders are properly selected and used
supervision □ only competent certified scaffolders erect, dismantle
° Working at and inspect scaffolding
heights □ scaffolding can be neither moved from its
° Platforms, place of installation (block the casters) nor
ladders and climbed
scaffolding □ all machinery with moving parts are sufficiently
° Lifting operations guarded
° Cranes, fork lifts, / interlocked and only competent operators operate /
etc. maintain it in line with the manufacturers' instructions
° Damaged or □ all openings are covered with unbreakable
defective PPE for material, barricaded and signage is in place
mechanical works □ all lifting equipment is regularly inspected as per
° Manual maintenance schedules
handling □ only competent and certified lifting operators operate
lifting equipment
□ all works, including those carried out by
contractors, are adequately risk assessed, supervised
and executed
□ working at heights is under permit to work system
□ only authorized personnel are present in the lifting
area
during lifting works and the area is barricaded / signed
□ all high-risk activities are controlled by a last minute /
point-of-work risk assessment before starting works
□ PPE in good condition for the identified tasks is
made available and all personnel are trained in its
use and maintenance
□ fall arrest PPE (lifelines, harness, etc.) are worn when
working at heights
° Inadequate risk ° Serious Ensure that:
Unloading of assessment injuries □ lifting equipment fit for tasks is used to avoid
panel onto ° Extreme weather (fractures, manual handling
prepared conditions amputations) □ all loads are fastened securely in line
foundation ° Portable ° Back injuries with manufacturers' instructions
electrical ° Fall into open holes □ all manufacturers' handling and installation
tools ° Impact with falling objects procedures
° ° Injury to third for equipment are strictly followed
Inadequate parties □ all openings are covered with unbreakable
ABB material, barricaded and signage is in place
supervision □ all lifting equipment is regularly inspected as per
° Working at maintenance schedules
heights □ only competent and certified lifting operators operate
° Platforms, lifting equipment

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 98 / 162
 ladders and □ all operators have undergone certification training in
scaffolding safe manual handling techniques
° Lifting operations □ all works, including those carried out by
° Cranes, fork lifts, contractors, are adequately risk assessed, supervised
etc. and executed
° Damaged or □ only authorized personnel are present in the lifting
defective PPE for area
mechanical works during lifting works and the area is barricaded / signed
° Manual □ all high-risk activities are controlled by a last
handling minute / point-of-work risk assessment before
starting works
□ PPE in good condition for the identified tasks is made
available and all personnel are trained in its use and
maintenance

4.6.11. High Mast Installation

In order to comply with project´s requirements and engineering design, it is necessary to supply,
installing, unloading and outfitting the High Mast and Light Fixtures.

[Link] Activity

 Movement of personnel using means of transport

 Personnel movements on foot
 Pick-up of materials from stores.
 Removal of packaging prior to installation
 Control of support base completed by third parties
 Installing mast
 Installing and connecting light fixtures
 Connecting cabling to control board
 Installing and connecting secondary earthing system
 Checks, tests and inspections according to doc. "QUALITY CONTROL PLAN–
ERECTION"

[Link] Resources

COMPONENTS AND ACCESSORIES

 Pole
 Light fixture mounting ring and mounting accessories
 Light fixtures
 Auxiliary cabling for electrical parts
 Control board
 Accessories for connection of secondary earthing system

EQUIPMENT

 Forklift truck
 Crane
 40 m-high mobile platform

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 99 / 162
  Power drill
 Torque wrenches
 Mechanic's tool box
 Electrician's tool box

[Link] Procedure – Tasks, Hazards, Consequences and Control Measures

Task Hazards Consequences Control Measures

Description

° Inadequate risk ° Serious injuries Ensure that:

Movement of assessment (fractures,  works conducted in places exposed to
personnel & amputations) extremes of temperature are
materials ° Extreme weather ° Back injuries adequately managed through a Heat
conditions ° Fall into open holes and Cold Weather Working Procedure
SAFELY,
° Fall from heights  all works, including those carried
using means ° Impact with moving
of transport out by contractors, are
objects adequately risk assessed,
° Impact with falling
supervised and executed
objects
 all high-risk activities are
controlled by a last minute /
° Injury to third parties
point-of- work risk assessment
before starting works
SAFELY ° Inadequate risk ° Serious injuries Ensure that:
assessment (fractures, amputations) □ works conducted in places exposed to
Personnel ° Extreme weather ° Exposure to UV- extremes of temperature are adequately
movement on conditions radiation managed through a Heat and Cold Weather
foot Working Procedure
□ all works, including those carried out by
contractors, are adequately risk assessed,
supervised and executed
all high-risk activities are controlled by a last minute
/ point-of-work risk assessment before starting
works
° Sharp edges and ° Serious injuries Ensure that:
Withdrawing moving parts (fractures, □ works conducted in places exposed to
materials ° Open holes amputations) extremes of temperature are adequately
from the ° Inadequate ABB ° Back injuries managed through a Heat and Cold Weather
stores supervision ° Fall into open holes Working Procedure
° Working at ° Fall from heights □ all works, including those carried out by
heights ° Impact with moving contractors, are adequately risk assessed,
° Platforms, objects supervised and executed
ladders and ° Impact with falling objects □ all high-risk activities are controlled by a
scaffolding last minute / point-of- work risk
° Lifting operations ° Injury to third parties assessment before starting works
° Cranes, fork lifts, etc.
° Damaged or defective
PPE for mechanical

works

° Sharp edges and ° Serious injuries Ensure that:

Removal of moving parts (fractures, □ works conducted in places exposed to
packaging ° Open holes amputations) extremes of temperature are adequately
prior to ° Inadequate ABB ° Back injuries managed through a Heat and Cold Weather
installation supervision ° Fall into open holes Working Procedure
° Working at ° Fall from heights □ all works, including those carried out by
heights ° Impact with moving contractors, are adequately risk assessed,
° Platforms, objects supervised and executed
ladders and ° Impact with falling objects □ all high-risk activities are controlled by a
scaffolding ° Injury to third last minute / point-of- work risk

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 100 / 162
 ° Lifting operations parties assessment before starting works
° Cranes, fork lifts, etc.
° Damaged or
defective PPE for
mechanical works
° Inadequate risk ° Serious Ensure that:
Control of assessment injuries □ lifting equipment fit for tasks is used to
support base ° Portable electrical (fractures, avoid manual handling
completed by tools amputations) □ all manufacturers' handling and installation
third parties ° ° Back injuries procedures
Inadequate ° Fall into open holes for equipment are strictly followed
ABB ° Slipping, triping, falling □ lone workers are knowledgeable and
supervision ° Impact with falling objects know their job details
° Hot works ° Injury to third □ appropriate communication channels are
° Working at heights parties available so that lone workers can contact
° Platforms, somebody else in case of an emergency
ladders and □ all operators have undergone certification
scaffolding training in safe
° Lifting operations manual handling techniques
° Cranes, fork lifts, etc. □ all works, including those carried out by
° Damaged or contractors, are adequately risk assessed,
defective PPE for supervised and executed
mechanical works □ suitable and sufficient permanent / temporary
° Manual handling lighting is
in place
□ all high-risk activities are controlled by a last
minute /
point-of-work risk assessment before starting
works
□ PPE in good condition for the identified
tasks is made available and all personnel are
trained in its use and maintenance
□ reflective vests PPE are worn by personnel
working in
poorly lit areas
° Inadequate risk ° Serious Ensure that:
Installing mast assessment injuries □ only electrical tools fit for tasks and
° Portable electrical (fractures, correctly voltage rated are used
tools amputations) □ ABB's electrical safety standard "The 7 Steps"
° ° Back injuries are strictly followed
Inadequate ° Fall into open holes □ lone workers are knowledgeable and
ABB ° Slipping, triping, falling know their job details
supervision ° Impact with falling objects □ appropriate communication channels are
° Hot works ° Injury to third parties available so that lone workers can contact
° Working at heights somebody else in case of an emergency
° Platforms, □ inspection and maintenance of tools are regularly
ladders and scheduled and damaged items are repaired or
scaffolding replaced
° Lifting operations □ all works, including those carried out by
° Cranes, fork lifts, etc. contractors, are adequately risk assessed,
° Damaged or supervised and executed
defective PPE for □ all high-risk activities are controlled by a last
mechanical works minute /
° Manual handling point-of-work risk assessment before starting
works
□ PPE in good condition for the identified tasks is
made
available and all personnel are trained in its use and
maintenance
° Inadequate risk ° Serious Ensure that:
Installing assessment injuries □ only electrical tools fit for tasks and
mounting ring ° Portable electrical (fractures, correctly voltage rated are used
tools amputations) □ ABB's electrical safety standard "The 7 Steps"
° ° Back injuries are strictly followed
Inadequate ° Fall into open holes □ lone workers are knowledgeable and
ABB ° Slipping, triping, falling know their job details
supervision ° Impact with falling objects □ appropriate communication channels are
° Hot works ° Injury to third parties available so that lone workers can contact

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 101 / 162
 ° Working at heights somebody else in case of an emergency
° Platforms, □ inspection and maintenance of tools are regularly
ladders and scheduled and damaged items are repaired or
scaffolding replaced
° Lifting operations □ all works, including those carried out by
° Cranes, fork lifts, etc. contractors, are adequately risk assessed,
° Damaged or supervised and executed
defective PPE for □ all high-risk activities are controlled by a last
mechanical works minute /
° Manual handling point-of-work risk assessment before starting
works
□ PPE in good condition for the identified tasks is
made
available and all personnel are trained in its use and
maintenance
° Inadequate risk ° Serious Ensure that:
Installing and assessment injuries □ only electrical tools fit for tasks and
connecting ° Portable electrical (fractures, correctly voltage rated are used
light fixtures tools amputations) □ ABB's electrical safety standard "The 7 Steps"
° ° Back injuries are strictly followed
Inadequate ° Fall into open holes □ lone workers are knowledgeable and
ABB ° Slipping, triping, falling know their job details
supervision ° Impact with falling objects □ appropriate communication channels are
° Hot works ° Injury to third parties available so that lone workers can contact
° Working at heights somebody else in case of an emergency
° Platforms, □ inspection and maintenance of tools are regularly
ladders and scheduled and damaged items are repaired or
scaffolding replaced
° Lifting operations □ all works, including those carried out by
° Cranes, fork lifts, etc. contractors, are adequately risk assessed,
° Damaged or supervised and executed
defective PPE for □ all high-risk activities are controlled by a last
mechanical works minute /
° Manual handling point-of-work risk assessment before starting works
□ PPE in good condition for the identified
tasks is made available and all personnel are
trained in its use and
maintenance
° Inadequate risk ° Electric shock injuries Ensure that:
Connecting assessment ° Electrocution □ only electrical tools fit for tasks and
cabling to ° Lone working ° Serious correctly voltage rated are used
control board ° Portable electrical injuries □ ABB's electrical safety standard "The 7 Steps"
tools (fractures, are strictly followed
° Inadequate ABB amputations) □ lone workers are knowledgeable and
supervision ° Back injuries know their job details
° Damaged or ° Fall from heights □ appropriate communication channels are
defective PPE for ° Exposure to UV-radiation available so that lone workers can contact
electrical works ° Injury to third parties somebody else in case of an emergency
□ inspection and maintenance of tools are regularly
scheduled and damaged items are repaired or
replaced
□ all works, including those carried out by
contractors, are adequately risk assessed,
supervised and executed
□ all high-risk activities are controlled by a last
minute /
point-of-work risk assessment before starting
works
□ PPE in good condition for the identified tasks is
made
available and all personnel are trained in its use and
maintenance
Installing ° Inadequate risk ° Electric shock injuries Ensure that:
and assessment ° Electrocution □ operations are conducted at the lowest possible
connecting ° Extreme ° Serious level
secondary weather injuries □ lifting equipment fit for tasks is used to avoid
earthing conditions (fractures, manual
system ° Portable electrical amputations) handling

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 102 / 162
 tools ° Back injuries □ all loads are fastened securely in line with
° ° Fall from heights manufacturers' instructions
Inadequate ° Exposure to UV-radiation □ when working at heights collective fall
ABB ° Injury to third parties protection (scaffolding, nets, railings) is mounted
supervision before starting works
° Hot works □ ladders are properly selected and used
° Working at heights □ only competent certified scaffolders erect,
° Platforms, dismantle and
ladders and inspect scaffolding
scaffolding □ scaffolding can be neither moved from
° Lifting operations its place of installation (block the casters)
° Cranes, fork lifts, etc. nor climbed
° Damaged or □ all structures, materials, etc. adjacent to
defective PPE for welding areas are adequately protected
mechanical works □ works conducted in places exposed to
extremes of temperature are adequately
managed through a Heat and Cold Weather
Working Procedure
□ only electrical tools fit for tasks and
correctly voltage rated are used
□ ABB's electrical safety standard "The 7 Steps"
are strictly followed
□ all lifting equipment is regularly inspected as per
maintenance schedules
□ only competent and certified lifting
operators operate lifting equipment
□ fire fighting equipment is installed near the area
where
hot works are conducted
□ inspection and maintenance of tools are regularly
scheduled and damaged items are repaired or
replaced
□ all works, including those carried out by
contractors, are adequately risk assessed,
supervised and executed
□ working at heights is under permit to work
system
□ hot works are under permit to work system
and carried out by competent personnel
□ only authorized personnel are present in
the lifting area during lifting works and the
area is barricaded / signed
□ all high-risk activities are controlled by a last
minute /
point-of-work risk assessment before starting
works
□ PPE in good condition for the identified
tasks is made available and all personnel are
trained in its use and maintenance
□ fall arrest PPE (lifelines, harness, etc.) are
worn when working at heights
□ face and respiratory PPE are worn when
performing hot works

4.6.12. MV and LV Cables and Terminations

To comply with project´s requirements and engineering design, it is necessary to supply, installing,
unloading and laying the power MV and LV cables with their terminations, markings and connections
to equipment and devices

[Link] Activity

 Movement of personnel using means of transport

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 103 / 162
  Personnel movements on foot
 Pick-up of materials from stores
 Removal of packaging prior to installation
 Preparation and preliminary activities for laying
 MV cable laying
 LV cable laying
 Identification and marking of MV cables
 Voltage Withstand and Insulation Tests according to ICE Standard 60502-2
 Connection to equipment and/or power board
 Inspection and tests

[Link] Resources

COMPONENTS AND ACCESSORIES

 MV cable reels
 MV terminal kits
 LV cable reels
 Accessories for LV cables
 Cable lugs, heat shrink, shields, glands, etc.

EQUIPMENT

 Forklift truck
 Reel trailer
 Reel stand
 Winch
 Spring to feed in cable
 Pipe cleaner brush
 Pilot wire
 Hemp rope
 Pull cable
 Rollers
 Pivot clamp
 Cable sock
 Lubricant
 Electrician's tool box
 Mechanic's tool box
 Gas cylinder
 Hydraulic press
 Hand press
 Cable cutter
 Heat shrink hot air gun
 Winders with extensions
 Instruments for electrical tests

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 104 / 162
[Link] Procedure – Tasks, Hazards, Consequences and Control Measures

Task Hazards Consequences Control Measures

Description

° Inadequate risk ° Serious injuries Ensure that:

Movement of assessment (fractures,  works conducted in places exposed to
personnel & amputations) extremes of temperature are
materials ° Extreme weather ° Back injuries adequately managed through a Heat
conditions ° Fall into open holes and Cold Weather Working Procedure
SAFELY, using
° Fall from heights  all works, including those carried
means of ° Impact with moving
transport out by contractors, are
objects adequately risk assessed,
° Impact with falling
supervised and executed
objects
 all high-risk activities are
controlled by a last minute /
° Injury to third parties
point-of- work risk assessment
before starting works
SAFELY ° Inadequate risk ° Serious injuries Ensure that:
assessment (fractures, amputations) □ works conducted in places exposed to
Personnel ° Extreme weather ° Exposure to UV- extremes of temperature are adequately
movement on conditions radiation managed through a Heat and Cold Weather
foot Working Procedure
□ all works, including those carried out by
contractors, are adequately risk assessed,
supervised and executed
all high-risk activities are controlled by a last minute
/ point-of-work risk assessment before starting
works
Pick-up of ° Sharp edges and ° Serious Ensure that:
materials moving parts injuries □ works conducted in places exposed to
from stores ° Open holes (fractures, extremes of temperature are adequately
° amputations) managed through a Heat and Cold Weather
Inadequate ° Back injuries Working Procedure
ABB ° Fall into open holes □ all works, including those carried out by
supervision ° Fall from heights contractors, are adequately risk assessed,
° Working at heights ° Impact with moving supervised and executed
° Platforms, objects □ all high-risk activities are controlled by a last
ladders and ° Impact with falling objects minute /
scaffolding ° Injury to third parties point-of-work risk assessment before starting
° Lifting operations works
° Cranes, fork lifts, etc.
° Damaged or
defective PPE for
mechanical works
° Sharp edges and ° Serious injuries Ensure that:
Withdrawing moving parts (fractures, □ works conducted in places exposed to
materials from ° Open holes amputations) extremes of temperature are adequately
the stores ° Inadequate ABB ° Back injuries managed through a Heat and Cold Weather
supervision ° Fall into open holes Working Procedure
° Working at ° Fall from heights □ all works, including those carried out by
heights ° Impact with moving contractors, are adequately risk assessed,
° Platforms, objects supervised and executed
ladders and ° Impact with falling objects □ all high-risk activities are controlled by a
scaffolding last minute / point-of- work risk
° Lifting operations ° Injury to third parties assessment before starting works
° Cranes, fork lifts,
etc.
° Damaged or defective
PPE for mechanical

works

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 105 / 162
 ° Sharp edges and ° Serious injuries Ensure that:
Removal of moving parts (fractures, □ works conducted in places exposed to
packaging prior ° Open holes amputations) extremes of temperature are adequately
to installation ° Inadequate ABB ° Back injuries managed through a Heat and Cold Weather
supervision ° Fall into open holes Working Procedure
° Working at ° Fall from heights □ all works, including those carried out by
heights ° Impact with moving contractors, are adequately risk assessed,
° Platforms, objects supervised and executed
ladders and ° Impact with falling objects □ all high-risk activities are controlled by a
scaffolding ° Injury to third last minute / point-of- work risk
° Lifting operations parties assessment before starting works
° Cranes, fork lifts,
etc.
° Damaged or
defective PPE for
mechanical works
Preparation ° Inadequate risk ° Electric shock injuries Ensure that:
and assessment ° Serious □ operations are conducted at the lowest possible
preliminary ° Extreme weather injuries level
activities for conditions (fractures, □ lifting equipment fit for tasks is used to avoid
laying ° Open holes amputations) manual
° ° Back injuries handling
Inadequate ° Fall from heights □ all loads are fastened securely in line with
ABB ° Impact with falling objects manufacturers' instructions
supervision ° Inhalation of hazardous □ when working at heights collective fall
° Working at heights substances protection (scaffolding, nets, railings) is mounted
° Platforms, ° Exposure to UV-radiation before starting works
ladders and ° Injury to third parties □ ladders are properly selected and used
scaffolding □ only competent certified scaffolders erect,
° Lifting operations dismantle and
° Cranes, fork lifts, etc. inspect scaffolding
° Damaged or □ scaffolding can be neither moved from
defective PPE for its place of installation (block the casters)
mechanical works nor climbed
° Manual handling □ all machinery with moving parts are sufficiently
guarded / interlocked and only competent
operators operate / maintain it in line with the
manufacturers' instructions
□ all openings are covered with
unbreakable material, barricaded and
signage is in place
□ all lifting equipment is regularly inspected as per
maintenance schedules
□ only competent and certified lifting operators
operate
lifting equipment
□ all works, including those carried out by
contractors, are adequately risk assessed,
supervised and executed
□ working at heights is under permit to work
system
□ only authorized personnel is present in the lifting
area
during lifting works and the area is barricaded /
signed
□ all high-risk activities are controlled by a
last minute / point-of-work risk assessment
before starting works
□ PPE in good condition for the identified
tasks is made available and all personnel are
trained in its use and maintenance
□ fall arrest PPE (lifelines, harness, etc.) are worn
when
working at heights
MV ° Inadequate risk ° Electric shock injuries Ensure that:
cable assessment ° Serious □ operations are conducted at the lowest possible
laying ° Extreme weather injuries level
conditions (fractures, □ lifting equipment fit for tasks is used to avoid

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 106 / 162
 ° Open holes amputations) manual
° ° Back injuries handling
Inadequate ° Fall from heights □ all loads are fastened securely in line with
ABB ° Impact with falling objects manufacturers' instructions
supervision ° Inhalation of hazardous □ when working at heights collective fall
° Working at heights substances protection (scaffolding, nets, railings) is mounted
° Platforms, ° Exposure to UV-radiation before starting works
ladders and ° Injury to third parties □ ladders are properly selected and used
scaffolding □ only competent certified scaffolders erect,
° Lifting operations dismantle and
° Cranes, fork lifts, etc. inspect scaffolding
° Damaged or □ scaffolding can be neither moved from
defective PPE for its place of installation (block the casters)
mechanical works nor climbed
° Manual handling □ all machinery with moving parts are sufficiently
guarded / interlocked and only competent
operators operate / maintain it in line with the
manufacturers' instructions
□ all openings are covered with
unbreakable material, barricaded and
signage is in place
□ all lifting equipment is regularly inspected as per
maintenance schedules
□ only competent and certified lifting operators
operate
lifting equipment
□ all works, including those carried out by
contractors, are adequately risk assessed,
supervised and executed
□ working at heights is under permit to work
system
□ only authorized personnel are present in the
lifting area
during lifting works and the area is barricaded /
signed
□ all high-risk activities are controlled by a
last minute / point-of-work risk assessment
before starting works
□ PPE in good condition for the identified
tasks is made available and all personnel are
trained in its use and maintenance
□ fall arrest PPE (lifelines, harness, etc.) are worn
when
working at heights
LV cable ° Inadequate risk ° Electric shock injuries Ensure that:
laying assessment ° Serious □ operations are conducted at the lowest possible
° Extreme injuries level
weather (fractures, □ lifting equipment fit for tasks is used to avoid
conditions amputations) manual
° Open holes ° Back injuries handling
° ° Fall from heights □ all loads are fastened securely in line with
Inadequate ° Impact with falling objects manufacturers' instructions
ABB ° Inhalation of hazardous □ when working at heights collective fall protection
supervision substances (scaffolding, nets, railings) is mounted before
° Working at heights ° Exposure to UV-radiation starting works
° Platforms, ° Injury to third parties □ ladders are properly selected and used
ladders and □ only competent certified scaffolders erect,
scaffolding dismantle and
° Lifting operations inspect scaffolding
° Cranes, fork lifts, etc. □ scaffolding can be neither moved from
° Damaged or its place of installation (block the casters)
defective PPE for nor climbed
mechanical works □ all machinery with moving parts are sufficiently
° Manual handling guarded / interlocked and only competent
operators operate / maintain it in line with the
manufacturers' instructions
□ all openings are covered with
unbreakable material, barricaded and

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 107 / 162
 signage is in place
□ all lifting equipment is regularly inspected as per
maintenance schedules
□ only competent and certified lifting operators
operate
lifting equipment
□ all works, including those carried out by
contractors, are adequately risk assessed,
supervised and executed
□ working at heights is under permit to work
system
□ only authorized personnel are present in the
lifting area
during lifting works and the area is barricaded /
signed
□ all high-risk activities are controlled by a last
minute /
point-of-work risk assessment before starting
works
□ PPE in good condition for the identified
tasks is made available and all personnel are
trained in its use and maintenance
□ fall arrest PPE (lifelines, harness, etc.) are worn
when
working at heights
Identification ° Inadequate risk ° Electric shock injuries Ensure that:
and marking assessment ° Serious □ operations are conducted at the lowest possible
of MV and ° Lone working injuries level
LV cables ° (fractures, □ lifting equipment fit for tasks is used to
Inadequate amputations) avoid manual handling
ABB ° Back injuries □ all loads are fastened securely in line with
supervision ° Fall into open holes manufacturers' instructions
° Damaged or ° Fall from heights □ when working at heights collective fall protection
defective PPE for ° Impact with falling objects (scaffolding, nets, railings) is mounted before
electrical works ° Inhalation of hazardous starting works
° Manual handling substances □ ladders are properly selected and used
° Injury to third parties □ only competent certified scaffolders erect,
dismantle and
inspect scaffolding
□ scaffolding can be neither moved from
its place of installation (block the casters)
nor climbed
□ all machinery with moving parts are sufficiently
guarded / interlocked and only competent
operators operate / maintain it in line with the
manufacturers' instructions
□ all openings are covered with
unbreakable material, barricaded and
signage is in place
□ all lifting equipment is regularly
inspected as per maintenance schedules
□ only competent and certified lifting operators
operate
lifting equipment
□ all works, including those carried out by
contractors, are adequately risk assessed,
supervised and executed
□ working at heights is under permit to work
system
□ only authorized personnel is present in the lifting
area
during lifting works and the area is barricaded /
signed
□ all high-risk activities are controlled by a last
minute /
point-of-work risk assessment before starting
works
□ PPE in good condition for the identified

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 108 / 162
 tasks is made available and all personnel are
trained in its use and maintenance
□ fall arrest PPE (lifelines, harness, etc.) are worn
when
working at heights
Voltage ° Inadequate risk ° Electric shock injuries Ensure that:
Withstand assessment ° Serious □ only electrical tools fit for tasks and
and ° Lone working injuries correctly voltage rated are used
Insulation ° (fractures, □ ABB's electrical safety standard "The 7 Steps"
Tests Inadequate amputations) are strictly followed
according to ABB ° Back injuries □ lone workers are knowledgeable and
ICE Standard supervision ° Fall into open holes know their job details
60502-2 ° Damaged or ° Fall from heights □ appropriate communication channels are
Check defective PPE for ° Impact with falling objects available so that lone workers can contact
integrity of electrical works ° Inhalation of hazardous somebody else in case of an emergency
insulation ° Manual handling substances □ inspection and maintenance of tools are
° Injury to third parties regularly scheduled and damaged items are
repaired or replaced
□ all works, including those carried out by
contractors, are adequately risk assessed,
supervised and executed
□ all high-risk activities are controlled by a
last minute / point-of-work risk assessment
before starting works
□ PPE in good condition for the identified tasks is
made
available and all personnel are trained in its use
and maintenance
Connection to ° Inadequate risk ° Electric shock injuries Ensure that:
equipment assessment ° Serious □ only electrical tools fit for tasks and
and/or power ° Lone working injuries correctly voltage rated are used
board ° (fractures, □ ABB's electrical safety standard "The 7 Steps"
Inadequate amputations) are strictly followed
ABB ° Back injuries □ lone workers are knowledgeable and
supervision ° Fall into open holes know their job details
° Damaged or ° Fall from heights □ appropriate communication channels are
defective PPE for ° Impact with falling objects available so that lone workers can contact
electrical works ° Inhalation of hazardous somebody else in case of an emergency
° Manual handling substances □ inspection and maintenance of tools are regularly
° Injury to third parties scheduled and damaged items are repaired or
replaced
□ all works, including those carried out by
contractors, are adequately risk assessed,
supervised and executed
□ all high-risk activities are controlled by a last
minute /
point-of-work risk assessment before starting works
□ PPE in good condition for the identified
tasks is made available and all personnel are
trained in its use and
maintenance

4.6.13. Reefer Sockets

In order to comply with project´s requirements and engineering design, it is necessary to supply,
installing, unloading and outfitting the cable ladders, reefer sockets, distribution boards, junction boxes,
light fixtures, panel onto prepared foundation

[Link] Activity
 Movement of personnel using means of transport
 Personnel movements on foot
 Pick-up of materials from stores.
 Removal of packaging prior to installation

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 109 / 162
  Marking out the panel's position
 Unloading for installation of cable ladders, reefer sockets, distribution
boards, junction boxes, light fixtures, panel onto prepared foundation
 Check according to doc.: "QUALITY CONTROL PLAN – ERECTION"

[Link] Resources

COMPONENTS AND ACCESSORIES

 Cable ladders,
 Reefer sockets,
 Distribution boards, Junction boxes,
 Light fixtures
 Conduit pipes with accessories

EQUIPMENT

 Movement rollers
 Pallet truck
 Reinforced panel movement trolley
 Marking out equipment
 Power drill
 Heavy duty power drill
 Material for support surface and movement of panels
 Crowbars
 Power extension leads
 Mechanic's tool boxes
 Electrician's tool boxes
 Folding resin ladders

[Link] Procedure – Tasks, Hazards, Consequences and Control Measures

Task Hazards Consequences Control Measures

Description

° Inadequate risk ° Serious injuries Ensure that:

Movement of assessment (fractures,  works conducted in places exposed
personnel & amputations) to extremes of temperature are
materials ° Extreme weather ° Back injuries adequately managed through a Heat
conditions ° Fall into open holes and Cold Weather Working Procedure
SAFELY, using
° Fall from heights  all works, including those carried
means of ° Impact with moving
transport out by contractors, are
objects adequately risk assessed,
° Impact with falling
supervised and executed
objects
 all high-risk activities are
controlled by a last minute /
° Injury to third parties
point-of- work risk assessment
before starting works
SAFELY ° Inadequate risk ° Serious injuries Ensure that:
assessment (fractures, amputations) □ works conducted in places exposed to
° Extreme weather ° Exposure to UV- extremes of temperature are adequately

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 110 / 162
 conditions radiation managed through a Heat and Cold Weather
Personnel Working Procedure
movement on □ all works, including those carried out by
foot contractors, are adequately risk assessed,
supervised and executed
all high-risk activities are controlled by a last
minute / point-of-work risk assessment before
starting works
° Sharp edges and ° Serious injuries Ensure that:
Withdrawing moving parts (fractures, □ works conducted in places exposed to
materials from ° Open holes amputations) extremes of temperature are adequately
the stores ° Inadequate ABB ° Back injuries managed through a Heat and Cold Weather
supervision ° Fall into open holes Working Procedure
° Working at ° Fall from heights □ all works, including those carried out by
heights ° Impact with moving contractors, are adequately risk assessed,
° Platforms, objects supervised and executed
ladders and ° Impact with falling objects □ all high-risk activities are controlled by a
scaffolding last minute / point-of- work risk
° Lifting operations ° Injury to third parties assessment before starting works
° Cranes, fork lifts,
etc.
° Damaged or defective
PPE for mechanical

works

° Sharp edges and ° Serious injuries Ensure that:

Removal of moving parts (fractures, □ works conducted in places exposed to
packaging prior ° Open holes amputations) extremes of temperature are adequately
to installation ° Inadequate ABB ° Back injuries managed through a Heat and Cold Weather
supervision ° Fall into open holes Working Procedure
° Working at ° Fall from heights □ all works, including those carried out by
heights ° Impact with moving contractors, are adequately risk assessed,
° Platforms, objects supervised and executed
ladders and ° Impact with falling objects □ all high-risk activities are controlled by a
scaffolding ° Injury to third last minute / point-of- work risk
° Lifting operations parties assessment before starting works
° Cranes, fork lifts,
etc.
° Damaged or
defective PPE for
mechanical works
Preparation ° Inadequate risk ° Serious Ensure that:
and assessment injuries □ lifting equipment fit for tasks is used to
installation ° Extreme (fractures, avoid manual handling
of mounting weather amputations) □ all manufacturers' handling and installation
brackets for conditions ° Back injuries procedures for
parts and/or ° Portable electrical ° Explosion and blast injury equipment is strictly followed
equipment tools ° Asphyxia, suffocation □ lone workers are knowledgeable and know their
(on ° ° Absorption of hazardous job details
holes/ceiling- Inadequate substances □ appropriate communication channels are
mounted ABB ° Injury to third parties available so that lone workers can contact
brackets supervision somebody else in case of an emergency
prepared by ° Hot works □ all operators have undergone certification
BAM) ° Working at heights training in safe
° Platforms, manual handling techniques
ladders and □ all works, including those carried out by
scaffolding contractors, are adequately risk assessed,
° Lifting operations supervised and executed
° Cranes, fork lifts, etc. □ suitable and sufficient permanent / temporary
° Damaged or lighting is in place
defective PPE for □ all high-risk activities are controlled by a last
mechanical works minute /
point-of-work risk assessment before starting
works
□ PPE in good condition for the identified
tasks is made available and all personnel
are trained in its use and maintenance

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 111 / 162
 □ reflective vests PPE are worn by personnel
working in
poorly lit areas
Installing ° Inadequate risk ° Serious Ensure that:
cable ladders assessment injuries □ only electrical tools fit for tasks and correctly
° Extreme (fractures, voltage rated are used
weather amputations) □ ABB's electrical safety standard "The 7
conditions ° Back injuries Steps" are strictly followed
° Portable electrical ° Explosion and blast injury □ lone workers are knowledgeable and know their
tools ° Asphyxia, suffocation job details
° ° Absorption of hazardous □ appropriate communication channels are
Inadequate substances available so that lone workers can contact
ABB ° Injury to third parties somebody else in case of an emergency
supervision □ inspection and maintenance of tools are
° Hot works regularly
° Working at heights scheduled and damaged items are repaired or
° Platforms, replaced
ladders and □ all works, including those carried out by
scaffolding contractors, are adequately risk assessed,
° Lifting operations supervised and executed
° Cranes, fork lifts, etc. □ all high-risk activities are controlled by a last
° Damaged or minute /
defective PPE for point-of-work risk assessment before starting
mechanical works works
□ PPE in good condition for the identified
tasks is made available and all personnel
are trained in its use and
maintenance
Installation of ° Inadequate risk ° Serious Ensure that:
power assessment injuries □ only electrical tools fit for tasks and correctly
distribution ° Extreme (fractures, voltage rated are used
boards weather amputations) □ ABB's electrical safety standard "The 7
conditions ° Back injuries Steps" are strictly followed
° Portable electrical ° Explosion and blast injury □ lone workers are knowledgeable and know their
tools ° Asphyxia, suffocation job details
° ° Absorption of hazardous □ appropriate communication channels are
Inadequate substances available so that lone workers can contact
ABB ° Injury to third parties somebody else in case of an emergency
supervision □ inspection and maintenance of tools are
° Hot works regularly
° Working at heights scheduled and damaged items are repaired or
° Platforms, replaced
ladders and □ all works, including those carried out by
scaffolding contractors, are adequately risk assessed,
° Lifting operations supervised and executed
° Cranes, fork lifts, etc. □ all high-risk activities are controlled by a last
° Damaged or minute /
defective PPE for point-of-work risk assessment before starting
mechanical works works
□ PPE in good condition for the identified tasks is
made
available and all personnel are trained in its use
and
maintenance
Installation of ° Inadequate risk ° Serious Ensure that:
Reefer assessment injuries □ only electrical tools fit for tasks and correctly
Sockets ° Extreme (fractures, voltage rated are used
weather amputations) □ ABB's electrical safety standard "The 7
conditions ° Back injuries Steps" are strictly followed
° Portable electrical ° Explosion and blast injury □ lone workers are knowledgeable and know their
tools ° Asphyxia, suffocation job details
° ° Absorption of hazardous □ appropriate communication channels are
Inadequate substances available so that lone workers can contact
ABB ° Injury to third parties somebody else in case of an emergency
supervision □ inspection and maintenance of tools are
° Hot works regularly
° Working at heights scheduled and damaged items are repaired or
° Platforms, replaced

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 112 / 162
 ladders and □ all works, including those carried out by
scaffolding contractors, are adequately risk assessed,
° Lifting operations supervised and executed
° Cranes, fork lifts, etc. □ all high-risk activities are controlled by a last
° Damaged or minute /
defective PPE for point-of-work risk assessment before starting
mechanical works works
□ PPE in good condition for the identified tasks is
made
available and all personnel are trained in its use
and maintenance
Installation of ° Inadequate risk ° Serious Ensure that:
junction boxes assessment injuries □ only electrical tools fit for tasks and correctly
(JB) ° Extreme (fractures, voltage rated are used
weather amputations) □ ABB's electrical safety standard "The 7
conditions ° Back injuries Steps" are strictly followed
° Portable electrical ° Explosion and blast injury □ lone workers are knowledgeable and know their
tools ° Asphyxia, suffocation job details
° ° Absorption of hazardous □ appropriate communication channels are
Inadequate substances available so that lone workers can contact
ABB ° Injury to third parties somebody else in case of an emergency
supervision □ inspection and maintenance of tools are
° Hot works regularly scheduled and damaged items
° Working at heights are repaired or replaced
° Platforms, □ all works, including those carried out by
ladders and contractors, are adequately risk assessed,
scaffolding supervised and executed
° Lifting operations □ all high-risk activities are controlled by a last
° Cranes, fork lifts, etc. minute /
° Damaged or point-of-work risk assessment before starting
defective PPE for works
mechanical works □ PPE in good condition for the identified tasks is
made
available and all personnel are trained in its use
and
maintenance
Installation of ° Inadequate risk ° Electric shock injuries Ensure that:
standard light assessment ° Electrocution □ only electrical tools fit for tasks and correctly
fixtures ° Extreme ° Serious voltage rated are used
weather injuries □ ABB's electrical safety standard "The 7
conditions (fractures, Steps" are strictly followed
° Portable electrical amputations) □ lone workers are knowledgeable and know their
tools ° Back injuries job details
° ° Fall from heights □ appropriate communication channels are
Inadequate ° Exposure to UV-radiation available so that lone workers can contact
ABB ° Injury to third parties somebody else in case of an emergency
supervision □ inspection and maintenance of tools are
° Hot works regularly scheduled and damaged items
° Working at heights are repaired or replaced
° Platforms, □ all works, including those carried out by
ladders and contractors, are adequately risk assessed,
scaffolding supervised and executed
° Lifting operations □ all high-risk activities are controlled by a last
° Cranes, fork lifts, etc. minute /
° Damaged or point-of-work risk assessment before starting
defective PPE for works
mechanical works □ PPE in good condition for the identified tasks is
made
available and all personnel are trained in its use
and maintenance

4.6.14. Cable Trays and Accessories for Earthing Lightning

In order to comply with project´s requirements and engineering design, it is necessary to supply,
installing, unloading and outfitting the cable trays and earthing lightning installations

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 113 / 162
[Link] Activity

 Movement of personnel& materials SAFELY, using means of transport

 SAFELY Personnel movement on foot
 Withdrawing materials from the stores
 Removal of packaging prior to installation
 Check positioning of metalwork supplied by third parties
 Cut Unistrut drawn elements to measure
 Positioning of suspended parts with relevant bracketing racks
 Positioning of cable tray ladder connected with jointing elements
 Installing and connecting secondary earthing system
 Checks, tests and inspections according to doc. "QUALITY CONTROL PLAN–
ERECTION"

[Link] Resources

COMPONENTS AND ACCESSORIES

 Straight cable ladders (L 3000)

 Accessories for assembly (plates + nuts & bolts)
 Unistrut , 41x41x2.5
 Bracketing racks
 Nuts & bolts for assembly, including:
 -bolts
 -washers
 Grover washers
 -nuts
 Accessories for connection of secondary earthing and lightning systems

EQUIPMENT

• Forklift truck
 Truck-mounted crane
 40 m-high mobile platform
 Mechanic's tool box
 Mobile scaffolding
 Power/battery-operated drill
 Folding fiberglass ladder with non-slip aluminum rungs

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 114 / 162
[Link] Procedure – Tasks, Hazards, Consequences and Control Measures

Task Hazards Consequences Control Measures

Description

° Inadequate risk ° Serious injuries Ensure that:

Movement of assessment (fractures,  works conducted in places exposed
personnel & amputations) to extremes of temperature are
materials ° Extreme weather ° Back injuries adequately managed through a Heat
conditions ° Fall into open holes and Cold Weather Working Procedure
SAFELY, using
° Fall from heights  all works, including those carried
means of ° Impact with moving
transport out by contractors, are
objects adequately risk assessed,
° Impact with falling
supervised and executed
objects
 all high-risk activities are
controlled by a last minute /
° Injury to third parties
point-of- work risk assessment
before starting works
SAFELY ° Inadequate risk ° Serious injuries Ensure that:
assessment (fractures, amputations) □ works conducted in places exposed to
Personnel ° Extreme weather ° Exposure to UV- extremes of temperature are adequately
movement on conditions radiation managed through a Heat and Cold Weather
foot Working Procedure
□ all works, including those carried out by
contractors, are adequately risk assessed,
supervised and executed
all high-risk activities are controlled by a last
minute / point-of-work risk assessment before
starting works
° Sharp edges and ° Serious injuries Ensure that:
Withdrawing moving parts (fractures, □ works conducted in places exposed to
materials from ° Open holes amputations) extremes of temperature are adequately
the stores ° Inadequate ABB ° Back injuries managed through a Heat and Cold Weather
supervision ° Fall into open holes Working Procedure
° Working at ° Fall from heights □ all works, including those carried out by
heights ° Impact with moving contractors, are adequately risk assessed,
° Platforms, objects supervised and executed
ladders and ° Impact with falling objects □ all high-risk activities are controlled by a
scaffolding last minute / point-of- work risk
° Lifting operations ° Injury to third parties assessment before starting works
° Cranes, fork lifts, etc.
° Damaged or defective
PPE for mechanical

works

° Sharp edges and ° Serious injuries Ensure that:

Removal of moving parts (fractures, □ works conducted in places exposed to
packaging prior ° Open holes amputations) extremes of temperature are adequately
to installation ° Inadequate ABB ° Back injuries managed through a Heat and Cold Weather
supervision ° Fall into open holes Working Procedure
° Working at ° Fall from heights □ all works, including those carried out by
heights ° Impact with moving contractors, are adequately risk assessed,
° Platforms, objects supervised and executed
ladders and ° Impact with falling objects □ all high-risk activities are controlled by a
scaffolding ° Injury to third last minute / point-of- work risk
° Lifting operations parties assessment before starting works
° Cranes, fork lifts, etc.
° Damaged or
defective PPE for
mechanical works
Laying the ° Inadequate risk ° Electric shock injuries Ensure that:
secondary assessment ° Electrocution □ operations are conducted at the lowest possible
earth ° Extreme weather ° Serious level

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 115 / 162
 cable conditions injuries □ lifting equipment fit for tasks is used to avoid
° Portable electrical (fractures, manual
tools amputations) handling
° ° Back injuries □ all loads are fastened securely in line with
Inadequate ° Fall from heights manufacturers' instructions
ABB ° Exposure to UV-radiation □ when working at heights collective fall
supervision ° Injury to third parties protection
° Hot works (scaffolding, nets, railings) is mounted before
° Working at heights starting works
° Platforms, □ ladders are properly selected and used
ladders and □ only competent certified scaffolders erect,
scaffolding dismantle and
° Lifting operations inspect scaffolding
° Cranes, fork lifts, etc. □ scaffolding can be neither moved
° Damaged or from its place of installation (block the
defective PPE for casters) nor climbed
mechanical works □ all structures, materials, etc. adjacent to
welding areas are adequately protected
□ works conducted in places exposed to
extremes of temperature are adequately
managed through a Heat and Cold Weather
Working Procedure
□ only electrical tools fit for tasks and correctly
voltage rated are used
□ ABB's electrical safety standard "The 7
Steps" are strictly followed
□ all lifting equipment is regularly
inspected as per maintenance
schedules
□ only competent and certified lifting operators
operate
lifting equipment
□ fire fighting equipment is installed near the area
where hot
works are conducted
□ inspection and maintenance of tools are
regularly
scheduled and damaged items are repaired or
replaced
□ all works, including those carried out by
contractors, are adequately risk assessed,
supervised and executed
□ working at heights is under permit to work
system
□ hot works are under permit to work system
and carried out by competent personnel
□ only authorized personnel is present in the lifting
area
during lifting works and the area is barricaded /
signed
□ all high-risk activities are controlled by a last
minute /
point-of-work risk assessment before starting
works
□ PPE in good condition for the identified
tasks is made available and all personnel
are trained in its use and maintenance
□ fall arrest PPE (lifelines, harness, etc.)
are worn when working at heights
□ face and respiratory PPE are worn when
performing hot works
Forming ° Inadequate risk ° Electric shock injuries Ensure that:
secondary assessment ° Electrocution □ operations are conducted at the lowest possible
(welded ° Extreme weather ° Serious level
derivation) conditions injuries □ lifting equipment fit for tasks is used to avoid
earth ° Portable electrical (fractures, manual
connections tools amputations) handling
° ° Injury to third parties □ all loads are fastened securely in line with

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 116 / 162
 Inadequate manufacturers' instructions
ABB □ when working at heights collective fall
supervision protection
° Hot works (scaffolding, nets, railings) is mounted before
° Working at heights starting works
° Platforms, □ ladders are properly selected and used
ladders and □ only competent certified scaffolders erect,
scaffolding dismantle and
° Lifting operations inspect scaffolding
° Cranes, fork lifts, etc. □ scaffolding can be neither moved
° Damaged or from its place of installation (block the
defective PPE for casters) nor climbed
mechanical works □ all structures, materials, etc. adjacent to
welding areas are adequately protected
□ works conducted in places exposed to
extremes of temperature are adequately
managed through a Heat and Cold Weather
Working Procedure
□ only electrical tools fit for tasks and correctly
voltage rated are used
□ ABB's electrical safety standard "The 7
Steps" are strictly followed
□ all lifting equipment is regularly inspected as per
maintenance schedules
□ only competent and certified lifting operators
operate
lifting equipment
□ fire fighting equipment is installed near the area
where hot
works are conducted
□ inspection and maintenance of tools are
regularly
scheduled and damaged items are repaired or
replaced
□ all works, including those carried out by
contractors, are adequately risk assessed,
supervised and executed
□ working at heights is under permit to work
system
□ hot works are under permit to work system
and carried out by competent personnel
□ only authorized personnel are present in the
lifting area
during lifting works and the area is barricaded /
signed
□ all high-risk activities are controlled by a last
minute /
point-of-work risk assessment before starting
works
□ PPE in good condition for the identified
tasks is made available and all personnel
are trained in its use and maintenance
□ fall arrest PPE (lifelines, harness, etc.)
are worn when working at heights
□ face and respiratory PPE are worn when
performing hot works
Forming ° Inadequate risk ° Electric shock injuries Ensure that:
secondary assessment ° Electrocution □ operations are conducted at the lowest possible
(compression) ° Extreme weather ° Serious level
earth conditions injuries □ lifting equipment fit for tasks is used to avoid
connections ° Portable electrical (fractures, manual
tools amputations) handling
° ° Injury to third parties □ all loads are fastened securely in line with
Inadequate manufacturers' instructions
ABB □ when working at heights collective fall
supervision protection
° Hot works (scaffolding, nets, railings) is mounted before
° Working at heights starting works

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 117 / 162
 ° Platforms, □ ladders are properly selected and used
ladders and □ only competent certified scaffolders erect,
scaffolding dismantle and inspect scaffolding
° Lifting operations □ scaffolding can be neither moved
° Cranes, fork lifts, etc. from its place of installation (block the
° Damaged or casters) nor climbed
defective PPE for □ all structures, materials, etc. adjacent to
mechanical works welding areas are adequately protected
□ works conducted in places exposed to
extremes of temperature are adequately
managed through a Heat and Cold Weather
Working Procedure
□ only electrical tools fit for tasks and correctly
voltage rated are used
□ ABB's electrical safety standard "The 7
Steps" are strictly followed
□ all lifting equipment is regularly
inspected as per maintenance
schedules
□ only competent and certified lifting operators
operate
lifting equipment
□ fire fighting equipment is installed near the area
where hot
works are conducted
□ inspection and maintenance of tools are
regularly scheduled and damaged items
are repaired or replaced
□ all works, including those carried out by
contractors, are adequately risk assessed,
supervised and executed
□ working at heights is under permit to work
system
□ hot works are under permit to work system
and carried out by competent personnel
□ only authorized personnel is present in the lifting
area
during lifting works and the area is barricaded /
signed
□ all high-risk activities are controlled by a last
minute /
point-of-work risk assessment before starting
works
□ PPE in good condition for the identified
tasks is made available and all personnel
are trained in its use and maintenance
□ fall arrest PPE (lifelines, harness, etc.)
are worn when working at heights
□ face and respiratory PPE are worn when
performing hot works
Installing ° Inadequate risk ° Electric shock injuries Ensure that:
earth spikes assessment ° Electrocution □ operations are conducted at the lowest possible
° Extreme weather ° Serious level
conditions injuries □ lifting equipment fit for tasks is used to avoid
° Portable electrical (fractures, manual
tools amputations) handling
° ° Back injuries □ all loads are fastened securely in line with
Inadequate ° Fall from heights manufacturers' instructions
ABB ° Exposure to UV-radiation □ when working at heights collective fall
supervision ° Injury to third parties protection (scaffolding, nets, railings) is
° Hot works mounted before starting works
° Working at heights □ ladders are properly selected and used
° Platforms, □ only competent certified scaffolders erect,
ladders and dismantle and
scaffolding inspect scaffolding
° Lifting operations □ scaffolding can be neither moved
° Cranes, fork lifts, etc. from its place of installation (block the
° Damaged or casters) nor climbed

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 118 / 162
 defective PPE for □ all structures, materials, etc. adjacent to
mechanical works welding areas are adequately protected
□ works conducted in places exposed to
extremes of temperature are adequately
managed through a Heat and Cold Weather
Working Procedure
□ only electrical tools fit for tasks and correctly
voltage rated are used
□ ABB's electrical safety standard "The 7
Steps" are strictly followed
□ all lifting equipment is regularly inspected as per
maintenance schedules
□ only competent and certified lifting
operators operate lifting equipment
□ fire fighting equipment is installed near the area
where hot
works are conducted
□ inspection and maintenance of tools are
regularly
scheduled and damaged items are repaired or
replaced
□ all works, including those carried out by
contractors, are adequately risk assessed,
supervised and executed
□ working at heights is under permit to work
system
□ hot works are under permit to work system
and carried out by competent personnel
□ only authorized personnel are present in
the lifting area during lifting works and the
area is barricaded / signed
□ all high-risk activities are controlled by a last
minute /
point-of-work risk assessment before starting
works
□ PPE in good condition for the identified
tasks is made available and all personnel
are trained in its use and maintenance
□ fall arrest PPE (lifelines, harness, etc.)
are worn when working at heights
□ face and respiratory PPE are worn when
performing hot works
Check ° Inadequate risk ° Serious Ensure that:
positioning assessment injuries □ operations are conducted at the lowest possible
of ° Extreme (fractures, level
metalwork weather amputations) □ lifting equipment fit for tasks is used to avoid
supplied by conditions ° Back injuries manual
third parties ° Portable electrical ° Fall into open holes handling
tools ° Impact with falling objects □ all loads are fastened securely in line with
° ° Injury to third parties manufacturers' instructions
Inadequate □ when working at heights collective fall
ABB protection
supervision (scaffolding, nets, railings) is mounted before
° Working at heights starting works
° Platforms, □ ladders are properly selected and used
ladders and □ only competent certified scaffolders erect,
scaffolding dismantle and
° Lifting operations inspect scaffolding
° Cranes, fork lifts, etc. □ scaffolding can be neither moved
° Damaged or from its place of installation (block the
defective PPE for casters) nor climbed
mechanical works □ all machinery with moving parts are sufficiently
° Manual handling guarded / interlocked and only competent
operators operate / maintain it in line with the
manufacturers' instructions
□ all openings are covered with
unbreakable material, barricaded and
signage is in place

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 119 / 162
 □ all lifting equipment is regularly inspected as per
maintenance schedules
□ only competent and certified lifting operators
operate
lifting equipment
□ all works, including those carried out by
contractors, are adequately risk assessed,
supervised and executed
□ working at heights is under permit to work
system
□ only authorized personnel are present in the
lifting area
during lifting works and the area is barricaded /
signed
□ all high-risk activities are controlled by a last
minute /
point-of-work risk assessment before starting
works
□ PPE in good condition for the identified
tasks is made available and all personnel
are trained in its use and maintenance
□ fall arrest PPE (lifelines, harness, etc.) are worn
when
working at heights
Cut Unistrut ° Inadequate risk ° Serious Ensure that:
drawn assessment injuries □ works conducted in places exposed to
elements to ° Extreme (fractures, extremes of temperature are adequately
measure weather amputations) managed through a Heat and Cold Weather
conditions ° Back injuries Working Procedure
° Open holes ° Fall into open holes □ all works, including those carried out by
° ° Impact with falling objects contractors, are adequately risk assessed,
Inadequate ° Injury to third parties supervised and executed
ABB □ all high-risk activities are controlled by a
supervision last minute / point-of-work risk assessment
° Hot works before starting works
° Working at heights
° Platforms,
ladders and
scaffolding
° Lifting operations
° Cranes, fork lifts, etc.
° Damaged or
defective PPE for
mechanical works
° Inadequate
emergency response
° Manual handling
Positioning of ° Inadequate risk ° Serious Ensure that:
suspended assessment injuries □ operations are conducted at the lowest possible
parts with ° Extreme (fractures, level
relevant weather amputations) □ lifting equipment fit for tasks is used to
bracketing conditions ° Back injuries avoid manual handling
racks ° Open holes ° Fall into open holes □ all loads are fastened securely in line with
° ° Impact with falling objects manufacturers' instructions
Inadequate ° Injury to third parties □ when working at heights collective fall
ABB protection
supervision (scaffolding, nets, railings) is mounted before
° Hot works starting works
° Working at heights □ ladders are properly selected and used
° Platforms, □ only competent certified scaffolders erect,
ladders and dismantle and
scaffolding inspect scaffolding
° Lifting operations □ scaffolding can be neither moved
° Cranes, fork lifts, etc. from its place of installation (block the
° Leakage of casters) nor climbed
hazardous □ all machinery with moving parts are sufficiently
chemicals guarded / interlocked and only competent
° Damaged or operators operate / maintain it in line with the

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 120 / 162
 defective PPE for manufacturers' instructions
mechanical works □ all openings are covered with
° Inadequate unbreakable material, barricaded and
emergency response signage is in place
° Manual handling □ all lifting equipment is regularly inspected as per
maintenance schedules
□ only competent and certified lifting operators
operate
lifting equipment
□ all works, including those carried out by
contractors, are adequately risk assessed,
supervised and executed
□ working at heights is under permit to work
system
□ only authorized personnel are present in
the lifting area during lifting works and the
area is barricaded / signed
□ all high-risk activities are controlled by a last
minute /
point-of-work risk assessment before starting
works
□ PPE in good condition for the identified
tasks is made available and all personnel
are trained in its use and maintenance
□ fall arrest PPE (lifelines, harness, etc.) are worn
when
working at heights
Positioning of ° Inadequate risk ° Electric shock injuries Ensure that:
cable tray assessment ° Serious □ operations are conducted at the lowest possible
ladder ° Extreme injuries level
connected weather (fractures, □ lifting equipment fit for tasks is used to avoid
with jointing conditions amputations) manual
elements ° Open holes ° Back injuries handling
° ° Fall from heights □ all loads are fastened securely in line with
Inadequate ° Impact with falling objects manufacturers' instructions
ABB ° Exposure to UV-radiation □ when working at heights collective fall
supervision ° Injury to third parties protection
° Hot works (scaffolding, nets, railings) is mounted before
° Working at heights starting works
° Platforms, □ ladders are properly selected and used
ladders and □ only competent certified scaffolders erect,
scaffolding dismantle and
° Lifting operations inspect scaffolding
° Cranes, fork lifts, etc. □ scaffolding can be neither moved
° Damaged or from its place of installation (block the
defective PPE for casters) nor climbed
mechanical works □ all machinery with moving parts are sufficiently
° Inadequate guarded / interlocked and only competent
emergency response operators operate / maintain it in line with the
° Manual handling manufacturers' instructions
□ all openings are covered with
unbreakable material, barricaded and
signage is in place
□ all lifting equipment is regularly inspected as per
maintenance schedules
□ only competent and certified lifting operators
operate
lifting equipment
□ all works, including those carried out by
contractors, are adequately risk assessed,
supervised and executed
□ working at heights is under permit to work
system
□ only authorized personnel is present in the lifting
area
during lifting works and the area is barricaded /
signed
□ all high risk activities are controlled by a last

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 121 / 162
 minute /
point-of-work risk assessment before starting
works
□ PPE in good condition for the identified
tasks is made available and all personnel
are trained in its use and maintenance
□ fall arrest PPE (lifelines, harness, etc.) are worn
when
working at heights

4.7 PAVEMENTS
In this section, the paving proposed by RHDHV for the new container terminal is reviewed and a new
proposal is outlined.

The CBR value at the bottom of the pavement section will be assumed to be larger than 15% according
to the soil improvement proposal in the yard area.

Two different pavement zones are determined as follows according to container handing methods,
equipment and vehicles throughout the terminal.

Photo 73 - Pavement Layout

4.7.1. Definitions

[Link] Pavement Zone 1: Container Stacks at RTG Yard (Row 1-4)

From the loads described in (5) the critical load is the one generated by the 6-high container stack in
blocks pattern.

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 122 / 162
As mentioned before, the CBR value in the natural soil is considered to be larger than 15% as a
consequence of the soil improvement in the esplanade. Hence, the 150mm sub-grade layer is not
necessary according to the principles of the BPA.

Using the Material Equivalent Factor of the BPA Manual, the section proposed in Erreur ! Source du
renvoi introuvable. is modified into potential alternative that provide an easier construction schedule:

80mm Concrete block pavement (CBP)

300mm Laying course material

370mm C25/30 Concrete Base

150mm sub-base material CBR>80%

>15% CBR Improved soil

Table 2 - Zone 1: Alternative Concrete Block Pavement Design Section.

[Link] Pavement Zone 2: Container Stacks at RTG Yard (Row 5-9)

From the loads described in (5) the critical load is the one generated by the 6-high container stack in
blocks pattern.

As mentioned before, the CBR value in the natural soil is considered to be larger than 15% as a
consequence of the soil improvement in the esplanade. Hence, the 150mm sub-grade layer is not
necessary according to the principles of the BPA.

Using the Material Equivalent Factor of the BPA Manual, the section proposed in Erreur ! Source du
renvoi introuvable. is modified into potential alternative that provide an easier construction schedule:

80mm Concrete block pavement (CBP)

300mm Laying course material

400mm C25/30 Concrete Base

150mm sub-base material CBR>80%

>15% CBR Improved soil

Table 3 - Zone 2: Alternative Concrete Block Pavement Design Section.

[Link] Run RTG Beams

The RTG runway beam will be as per the reference design but will include a C8/10 CBGM base (min
80 mm; max 110 mm) plus a 150 mm subbase material with CBR > 80%. This solution will be consistent
with the overall pavement project.

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 123 / 162
[Link] GATE COMPLEX ROADS

The next figure identifies the pavement surfaces to be installed at the Gate Complex.

AREA DE LOSA
AREA DE CIRCULACION
AREA DE ANDENES
- - - - - - - - - -ML
- - -BORDILLO
-
M2 URBANISMO

Photo 74 – Gate Complex Pavement Layout

According to the Clarification N° 23 The solution for this area there will be the described in the document
“20181217 INFORME DE DISEÑO DE PAVIMENTO Patio 6”, into the numeral 2.1.1 conclusion and
recommendations, the solution consists in a Pavement milling of 5.0 cm.

In this area, work will begin with milling of the existing pavement structure on the Road’s area, removal
and rethinking of the new layout of the Gate Area complex. Once these preliminary works have been
completed, in the road area (indicated in Magenta) will be carried out to subsequently place the
infrastructure to supply the needs of the Gates, OCR and TSB areas. Once these works are completed,
the pavement structure will be replaced according to design; at the same time the approach slabs for
the Gates area and OCR area will be built and finally the rolling layer will be placed

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 124 / 162
4.7.2. Resources

[Link] Common Base (C25/30) and Sub-base (CBR >80%)

Materials:

• Sub base CBR>80%

• C 25/30 (concrete base)

Personnel:

• Superintendent
• Site engineer (yard)
• Site engineer
• Quality control manager
• Health & safety manager
• Worker
• Heavy machine operator

Equipment and tools:

• GPS based total station

• Hand operated tamper / vibratory plate compactor
• Roller
• Dump truck
• Excavator
• Motor grader
• Nuclear densimeter

[Link] Concrete Block Pavers - CBP

Materials:

• SAND (according to ASTM C33)

• CONCRETE PAVERS (200mm*100mm*80mm) (T = 3.8 mpa)
• GEOTEXTILE 450g/m2

Personnel:

• Superintendent
• Site engineer (yard)
• Site engineer
• Quality control manager
• Health & safety manager
• Worker (concrete, rebar, formwork)
• Heavy machine operator

Equipment and tools:

• Trucks
• Forklift

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 125 / 162
 • Vibrator roller
• Bobcat
• Hand tools
• Total station
• Level

[Link] Reinforced Concrete

Materials:

• Concrete
• Rebar fy 4200 kg/cm2

Personnel:

• Superintendent
• Site engineer (yard)
• Site engineer
• Quality control manager
• Health & safety manager
• Worker (concrete, rebar, formwork)
• Heavy machine operator

Equipment and tools:

• Survey equipment
• Excavator
• Dump truck
• Loader
• Roller
• Sprinkler
• Concrete mixer truck

4.7.3. Procedure

[Link] Common Base (C25/30) and Sub-base (CBR >80%)

The Base and sub base will be prepared carefully, in order to allow a pavement structure of an adequate
and uniform thickness. This allows to provide a homogeneous bond between the concrete slab, or
pavers, and its foundation which is important for the later behavior of the pavement structure.

It will always be avoided that water is sucked from the cement paste into the substructure or the base.

This will be accomplished by applying a plastic sheet on the substructure of the pavement. The latter
work will be done with care, to prevent the sheet from tearing or being pulled loose by the wind

[Link].1 CONCRETE BASE C25/30

i. The template installation should be stable, horizontal and vertical, and the adjacent
template joints should be tight and smooth, and there should be no leakage or height
inequality.

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 126 / 162
 ii. -There may be a gap between the supported formwork and the ground, and we will use cement
mortar to seal the gap before pouring.
iii. –C25/30 concrete should be mixed in strict accordance with the design mix ratio. After the
mixing procedure is completed, transport the concrete by a concrete tanker.
iv. -It should be sprinkle water on the surface of the pouring area 10-20 minutes before pouring
the concrete. After the concrete is transported to the site, it has to pouring directly from the
tanker into the template, and make it uniform by mason.
v. After the concrete is poured, using vibrating bar for vibrating it ，and at the same time
continuing to pour new concrete.
vi. -After the concrete is vibrated and compacted, roughly leveling it with the scraper first. After the
moisture of the concrete surface layer evaporates 80%, then finish the surface. Polishing the
surface twice with a sander; using mason for surface finishing.
vii. -After completing the surface finishing, should cover the concrete with geotextile and spray
water on it to keep the concrete wet at least 7 days for maintenance.
viii. When constructing the site, it is planning to support the template to be 24m long and 6m wide.
This size is a typical construction size. When the length and width are not met, it is adjusted
according to the site conditions.
ix. -All construction joints and expansion joints are covered with a geotextile (150g/cm3) before
laying the medium coarse sand and glued to the concrete surface with bitumen.

[Link].2 Sub-base CBR > 80%


i. Location of facilities shall be directed by land surveying crew according to set up layout.
ii. Surveying benchmarks shall be set-out by Land surveying crew.
iii. According to the location to be backfilled and compacted, the sub base will be placed, in uniform
layers to a depth no longer than 250 mm and compacted using (depending of each case) a
hand operated tamper, plate compactor or roller compactor until reaching level indicated in
drawings and the density solicited. (In places that do not allow the use of heavy machine to
compact, the layers should not be made deeper than 150 mm)
iv. In any case the Contractor must take care the Proctor test results and monitor the moisture of
the material prior to the compaction and in the middle of the process to obtain an optimal
compaction by layer.
v. After the compaction of each layer a surveyor team will record the levels to be able tracking all
the process.

[Link] Concrete Block Pavers - CBP

[Link].1 SETTING OUT

Consideration will be given to the laying pattern and the orientation of laying pattern. This will be
provided by the Designer and shown on the detailed drawings. However, it is often the case with
slabs/flags, that a width may be specified and random lengths at the pavior's discretion. Setting out of
datum points will be materialized in order to assist in to achieving falls, straight lines, curves etc.

For dimensionally large project as this one, in order to ensure consistent alignment, it will be helpful to
set out a reference grid using flush nails or paint, typically on a 10m x 10m grid or bigger over the base
surface. Major lines are also to be set out according to datum points.

Areas of paving demarcated by boundaries such as change in level, change in pattern or type of paving
unit or other perimeter feature will have the lengths of all sides and diagonals measured at final surface
levels, to confirm in advance of laying that the effect of longitudinal falls, cross falls, setting out errors

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 127 / 162
or other unforeseen factors will not prevent the specified paving patterns being achieved using the
paving elements provided for the contract.

When perimeters and major lines have been confirmed and feasibility checked, minor lines should be
set up at intervals, in advance of laying, to represent a multiple of paving unit width plus joint width. This
will prevent the pattern locally overtaking the major lines of the pattern and also prevents joint widths
increasing abnormally.

Paving materials should be stored in an appropriate location, to minimize trafficking on the prepared
base during installation.

[Link].2 LAYING PATERN

For a rigid pavement construction, laying pattern generally makes a negligible contribution to the overall
structural integrity of the pavement. If excessive strain occurs within the pavement surface course, due
to thermal contraction or movement of the base, cracks might become focused along a continuous line
of joints. However, this is not a problem which laying pattern may prevent.

The laying pattern must conform to that given in the drawings. Some simple rules need to be followed:

 A cut is required at any change in surface shape to prevent lipping. It is accepted that this can
lead to triangular shapes which contravene the rules about cutting given below.
 Straight joints are usually provided in one direction but stepped joints in the other direction.
 Joint widths must be within the permitted range.
 With cropped setts, sufficient space must be allowed everywhere for grout to run easily into the
joint.

The standard details at drainage features and other ironwork must be followed, especially if an
expansion joint detail is specified.

[Link].3 JOIN WIDTH

When laying a rigid pavement, joint width is an important factor.

The purpose of the mortar joint is to prevent ingress of water during the service life of the pavement
and to provide structural integrity to the surface course. Jointing mortar contributes both strength and
flexibility to the pavement surface.

Minimum joint width is a function of both the maximum particle size within the jointing mortar and the
degree of flexibility it is intended to provide in conjunction with the paving units. Joint width is to be set
by the detailed drawings.

[Link].4 CUTS AND CUTTING IN

The paved area will be covered as far as possible with full sized paving units.

Longer units will be employed at ends of rows, in preference to cutting down standard units so that
length is less than the shortest specified unit length.

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 128 / 162
Where trimming will be required, cut sizes smaller than a third of the original plan size of the paving unit
will be avoided as possible. Cut units will be laid concurrently as paving proceeds. With rigid paving it
is not permissible to leave gaps in the surface course, to be filled at a later time. If this is unavoidable,
e.g. because of the unavailability of a cover, all bedding mortar not covered by a unit will be removed.

[Link].5 PREPARING THE BASE

Rigid pavements require a sound, strong physical connection between base material and bedding
mortar. For a bound base this means an effective adhesion bond, for an unbound base this means an
effective frictional connection. Both require cleanliness.

For the purpose the pavement will be laid upon a bound base, the surface will be cleaned of all debris
and dust prior to the laying of the bedding mortar. Cleaning with water will be done removal of all loose
materials. Any contaminants such as hydraulic or fuel oil spillage will be thoroughly removed, using
chemical and mechanical means as required.

The base will be checked for level to ensure the laying course will be the correct thickness. If is too high
material will be removed. If it is too low the whole base will be removed and replaced or a proprietary
product solution may be used.

[Link].6 PREPARING PAVING UNITS

A rigid pavement requires a strong adhesion bond between paving units and both bedding and jointing
mortar. Paving units will have all dust and debris removed from all faces. Cleaning with water will be
done at a timing sufficiently short prior to laying in order to avoid recontamination.

[Link].7 INSTALATION OF PAVING UNITS

Before paving starts all necessary tools will be prepared and ready for use. The essential tools typically
required for this procedure are:

 Mixing machine for bedding mortar.

 Barrow for transporting bedding mortar from mixer to point of laying.
 Shovel for moving bedding mortar and general handling of dry or blended mortar products.
 Trowel for preparing and levelling bedding mortar.
 Tub and mixing equipment for adhesive priming mortar.
 Brush or trowel for applying adhesive priming mortar.
 Tub or bucket for cleaning water.
 Sponge for cleaning.
 Short wooden level.
 Long level.
 Sett hammer – weight relevant to size of paving unit.
 String lines for setting out rows and patterns.
 Cutting equipment if required.

A small sample area will be prepared to confirm that the specified mix is suitable for the paving units
being laid and to confirm surcharge height.

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 129 / 162
Bedding mortar will be laid to a previously defined surcharge height to allow for compaction to line and
level when tamping down the paving element, however a lower height may be adopted if the test
procedure confirms that full contact has been made between bedding mortar and the underside of the
paving unit and that no voids exist in the bedding mortar. A close visual examination of the laid bedding
will confirm this fact when a laid paving unit is lifted as a check.

The surface of the cement treated base is to be coated with the bedding mortar laid out for a minimum
width of two rows of paving units, to the required surcharge height. This is to ensure adequate stability
of the freshly laid bedding mortar adjacent to paving units being placed and aligned.

The bedding mortar shall not at any time be spread in advance of more than 4 rows of paving units.
The fresh bedding mortar will be levelled prior to placement of each paving unit using either a trowel or
the blade of the sett hammer.

The underside of the paving unit is to be coated with priming mortar immediately prior to the paving unit
is being placed onto the fresh bedding mortar. Priming mortar will be applied by brushing or trowel. In
every case it will be ensured that the underside of the paving unit is fully wetted out with the adhesive
priming mortar and that the surface is fully coated.

Adhesive priming mortar will be applied to a thickness according to manufacturer’s instructions, and will
not under any circumstances be applied to one or more paving units in advance of their being placed
on the bedding mortar.

Paving units will be hammered firmly to line and level without delay and thereafter they will not to be
disturbed.

The short level will be used to slide across the freshly laid paving units and check for lips and local level.
The long level will be used to check level over wider areas.

[Link].8 PROVISION OF CONTRACTION JOINTS.

Contraction joints in the surface course of a pavement laid over a non-rigid bound base, such as a
cement treated base, shall be positioned where it is most convenient for the setting out and laying
pattern of the surface course.

A vertical strip of polythene membrane will be introduced within a line of open joints along the line of
the proposed contraction joint. The polythene strip will be set within the bedding mortar, for its full depth,
and allowed to stand freely upright in the open joint, for its full height. None of the polythene strip is
allowed to protrude above the surface of the pavement. Jointing mortar will be used to fill the joint void,
uncontrolled, finding its own level each side of the polythene membrane thus forming an induced break
or contraction joint.

[Link].9 GROUND OF MORTAR JOINTS.

Fresh pavement jointing mortar will be a pourable self-compacting grout which, when applied, fills the
joint in one operation.

Paving units will not have their joints filled to within 2 mm to 3 mm of their top surface. Jointing mortar
shall not be allowed to rise to be flush with the pavement surface.

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 130 / 162
The application will be done by pouring the grout over the area and using a squeegee to spread and
guide the slurry into the open joints. Alternatively, and where required, the application will also be
achieved by using a can with a fine nozzle, or by injecting the joint with a handgun.

Before starting to grout the joints it will be ensured that necessary tools are prepared and ready for use.
The essential tools typically required for this procedure are:

 Mixing machine for jointing mortar.

 Barrow for transporting jointing mortar from mixer to point of work.
 Alternatively: Tub and mixing equipment for jointing mortar.
 Suitable squeegee for spreading fresh mortar.
 A pressurized fresh water supply with a flexible hose capable of reaching all extents of the area
to be jointed.
 Optional – a grout cleaning machine.

Joints shall be clean and cleared of all foreign matter. The area to be jointed shall be thoroughly soaked
with clean water and maintained in a wet condition until jointing mortar is applied.

Jointing mortar shall be mixed to a free-flowing liquid slurry grout. When using a proprietary mortar
product, the manufacturer’s method statement shall be consulted and adopted.

Freshly mixed mortar will be spread over the surface whilst the surface is wet and the mortar will be
forced into the open joints using the squeegee.

Water shall be applied to the surface at any time in the form of a fine spray, to prevent drying of the
mortar on the surface. When further settling of the fresh mortar within the joints has ceased, excess
mortar will be removed using the squeegee.

Water will be immediately applied to the surface in the form of a fine spray, taking care not to disturb
the mortar in the joints, until the surface is thoroughly wetted. Water and excess water will then be
removed using the squeegee.

The process of wetting and removal will be repeated; water always being applied to the surface in the
form of a fine spray, taking care not to disturb the mortar in the joints. The surface is thereafter
maintained in a damp condition by periodic application of water in the form of a fine spray. It shall never
be allowed to dry, even in small places, until final cleaning is done. The surface will be rinsed clear with
clean water after sufficient time has elapsed for the joint mortar to have become sufficiently stable to
resist action of cleaning.

[Link] Reinforced Concrete

[Link].1 MIXING AND TRANSPORT CONCRETE

The concrete mixing plant will have sufficient capacity in order to be able to continuously supply
concrete to the paving machines. The ready-mix, its constituents and admixtures will be previously
tested and approved before its application.

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 131 / 162
The loading equipment for the materials shall be in good condition and shall have sufficient capacity to
be able to continuously feed the bins. The bucket of the loaders shall not be wider than the bins. The
content of the cement silos and the water tank are in proportion to the production rates.

A communication system between the concrete mixing plant and the construction site will be put in
place in order to coordinate the batching and paving operations.

Sufficient trucks will be available to continuously supply the paving machines. The number of trucks will
depend on the yield at the construction site, the loading capacity of the trucks and the cycle time (i.e.
the transport time plus the time required to load and unload a truck). The loading capacity and the type
of truck to be used will depend on the nature of the work, the haul roads and the concrete paving
machines.

The necessary measures will be taken to prevent changes of the water content and temperature of the
concrete during transport.

[Link].2 FORMWORK AND STEEL REINFORCEMENT PLACING

A formwork will be placed, aligned and leveled according to the detailed designs. In order to place the
side forms properly the alignment of the runway has to be staked out carefully. This will be accomplished
by driving iron rods firmly into the subgrade soil or the base at a spacing of maximum 5 m. The
elevations corresponding to the top of the forms will be marked on the rods and they are connected
with a string line that will be coincident to the top of the forms.

Steel assembly will be done ensuring that the type and number of bars is in accordance with the design
and specification.

The longitudinal and transverse reinforcement will be transported, unloaded and stored at the
construction site in compliance with specific rules:

 delivery in packs that contain exactly the number of bars that are required to make the
reinforcement mesh for the entire pavement width;
 unloading these packs with a crane equipped with a loading beam to uniformly suspend the
steel pack so as to avoid permanent deformation;
 storage of the packs in clean areas.

The transverse reinforcement is placed on the base, at intervals that are checked with templates.
Subsequently the longitudinal bars are laid on the transverse reinforcement bars, in such a way that
bar splices are skewed at an angle that depends on the width of the pavement. At each splice the two
bars are tied together with two iron wires.

[Link].3 PLACING THE CONCRETE

All equipment necessary for executing the paving will be present on site and has to function properly.
This concerns primarily: manual needle vibrators and vibrating screed, equipment for floating the
concrete surface, for applying the curing compound, for sawing the joints, etc.

This equipment will meet both the requirements for quality and for the envisaged rate of production.

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 132 / 162
The profile of the finishing equipment has to be even, in order to obtain a good final pavement
smoothness. To check this, a gauge will be placed at each end of the screed to be controlled.
Subsequently, a string is tensioned between the two gauges and the distance between the string and
the finishing surface of the screed is measured at various points. Another method that may be used
consists of checking the evenness with a level and levelling rod.

The consolidation equipment will be able to generate uniform vibrations with the right frequency and
amplitude.

The concrete will be supplied by truck mixers and will be offloaded between the forms and spread with
the help of a crane or an excavator. The drop height of the concrete mix will be limited and the concrete
poring will happen gradually so as to prevent segregation or pre-consolidation. The supply and the
placement of the concrete will be synchronized to the same rate, on the one hand to avoid interruptions
in the placement of the concrete and on the other hand to avoid that too much time is elapsing between
depositing and finishing the concrete.

The concrete will be consolidated with manual needle vibrators and a vibratory screed. The
consolidation will happen first with the manual vibrators, in particular along the edges and subsequently
with the vibratory screed. The freshly placed concrete edges will be strutted by the side forms or by
adjacent linear elements or existing paving slabs.

The finishing will be completed by using a hand float attached to a handle by a double hinge.

[Link].4 EXECUTION OF JOINS.

All the equipment that is necessary to make joints in the fresh or hardened concrete will be present at
the construction site.

The saw blades will be suitable to the quality of the concrete, i.e. to the hardness and the abrasion
resistance of the aggregates.

The beam for making a construction joint shall be rigid and shall allow the realization of a straight joint
perpendicular to the axis of the runway. This beam will be adapted to the type of pavement.

Contraction joints

Crack onsets will be executed to avoid uncontrolled cracking of the concrete by shrinkage. Contraction
joints have a crack onset will extend to a depth defined in the detailed drawings. These will be made by
sawing. The saw cutting shall occur as soon as possible, between 5 and 24 hours after placement of
the concrete and ensuring that the concrete has hardened sufficiently in order to prevent the edges of
the joint from being damaged.

After having made the crack onset, the concrete surface along the joint shall be smoothened again.
However, manual corrections shall be kept to a minimum since they can cause spalling of the joint
edges later.

Expansion joints

Expansion joints will be executed according with the detailed drawings. The execution of expansion
joints will require special attention as per the following:

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 133 / 162
  the wooden joint filler board shall be firmly attached to the base by means of metal stakes, so
that it cannot move while the concrete is being placed;
 the height of the joint filler board shall be slightly (2 to 3 cm) shallower than the thickness of the
concrete slab, in order not to hinder the placement of the concrete. As soon as the concrete
has been placed, the concrete above the joint filler board shall be removed over a width at least
equal to the thickness of the board, so that no “concrete arch” is made at the top of the joint;
 expansion joints shall always be provided with dowels. At one end of each dowel a cap filled
with a compressible material accommodates the movements of the concrete.

Construction joints

Construction joints - also called end-of-day or working joints – will be executed at the end of the daily
production or when the paving process will be foreseen to be interrupted for at least 2 hours. The face
of these joints will be plane, vertical and perpendicular to the axis of the pavement. These joints will
always be doweled.

Upon resuming the paving, the fresh concrete is placed against the concrete that has already hardened.
The concrete will be consolidated on both sides of the joint with a separate manual needle vibrator.

Sealing the joints

Joints are to be sealed with a joint sealant to prevent water infiltration under the paving slabs in the
future. To this end, hot or cold joint sealants or prefabricated joint can be used. To achieve a durable
seal, this work will be done with the utmost care.

4.8 ROADMARKING
The scope of this construction method is proposed to complete the line marking on all the pavements
inside the port.

4.8.1. Resources

Materials:

• Primer
• High traffic paint

Personnel:

• Superintendent
• Site engineer (yard)
• Site engineer
• Quality control manager
• Health & safety manager
• Worker
• Equipment operator

Equipment and tools:

• Air compressor
• Hydro cleaner

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 134 / 162
 • Spreaders (pressure paint applicators)

4.8.2. Procedure

• Prior to any paint application, the surface will be cleared of all dirt, loose material and other
contaminants. A hydro cleaner machine will be used to clean the area. If any particles are
needed to remove, an air compressor will be used; additionally, the area should be completely
dry. If it is not, the contractor will wait until is dry or will use a drying machine.
• Before applying the paint, a primer will be applied all over the painting area. The primer
thickness is around 25 microns.
• The area will be paint with traffic paint by using Spreader pressure painting equipment and
template for ensuring the shape of the symbols and lines, please refer to pictures below. The
control speed and the thickness of the paint must be pre-calibrate in the machine and tested;
The surface will be paint in two coats. It will have a minimum thickness of 350 microns for each
layer of line marking. Depends on the planning the two coats can be painted in the same shift,
waiting the required full drying time for the product used. Or, in a big area all the line marks will
be done the first layer and other day finish with the second coat.
• Immediately after the paint be placed, should be spread the glass bead all over the painted
area. The glass beads are type 1. The beads will be embedded in the paint by gravity.
• All the area must be signaled to prevent the pass of any vehicle or person.

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 135 / 162
4.9 BUILDINGS

4.9.1. Main Buildings - Definitions

[Link] CSW - Cold Storage Warehouse

Photo 75 - Cold Storage Warehouse Layout

Rooms Material Datasheet

 Walls
To this building will be considered metallic panel system with PIR thermal core to the interior walls, to
the exterior walls will be considering metallic panel with a purlins of reinforcement structure to the
cladding.

 Floors
The floor will be made of concrete slab, and a dry shake topping, except the -25-degree cell this will
be had an epoxy paint over.
The floors of the cells area will be having a PIR panel bellow the concrete slab.

 Ceiling
To the cell ceilings of PIR panel will be supported on the top of adjacent walls, where necessary,
suspended from the main structure steel work.
To the rest of the warehouse the ceiling will be a drywall water resistant.

 Roof
The roof Panel will be made of PIR insulated with a steel cover.

 Doors and windows

All the doors for this building will be insulated, except the machine areas.
The windows will be made with a double glazed and cover with an aluminum louver.

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 136 / 162
  Finishing datasheet

750 - COLD STORAGE WAREHOUSE

Number Name Area Wall Finish Ceiling Finish Floor Finish
1 Cold storage cell 1 313 m² PIR PANEL 100MM PIR PANEL 100MM Concrete with dry shake topping
2 Cold storage cell 2 313 m² PIR PANEL 100MM PIR PANEL 100MM Concrete with dry shake topping
3 Cold storage cell 3 314 m² PIR PANEL 100MM PIR PANEL 100MM Concrete with dry shake topping
4 Cold storage cell 4 314 m² PIR PANEL 100MM PIR PANEL 100MM Concrete with dry shake topping
5 Cold storage cell 5 314 m² PIR PANEL 100MM PIR PANEL 100MM Concrete with dry shake topping
6 Cold storage cell 6 314 m² PIR PANEL 100MM PIR PANEL 100MM Concrete with dry shake topping
7 Cold storage cell 7 314 m² PIR PANEL 100MM PIR PANEL 100MM Concrete with dry shake topping
8 Cold storage cell 8 314 m² PIR PANEL 100MM PIR PANEL 100MM Concrete with dry shake topping
9 Cold storage cell 10 314 m² PIR PANEL 100MM PIR PANEL 100MM Concrete with dry shake topping
10 Cold storage cell 9 314 m² PIR PANEL 100MM PIR PANEL 100MM Quartz epoxy flooring finishing
11 TRANSFORMER 39 m² PIR PANEL 60MM NONE Concrete with dry shake topping
ROOM
12 HVAC ROOM 357 m² PIR PANEL 60MM NONE Concrete with dry shake topping
13 PRE- 124 m² PIR PANEL 100MM PIR PANEL 100MM Quartz epoxy flooring finishing
CHAMBER(CELL10)
14 CORRIDORS 1860 m² PIR PANEL 60MM RH GYPSUM Concrete with dry shake topping
15 Pick Up / Lay Down 1254 m² PIR PANEL 60MM RH GYPSUM Concrete with dry shake topping
Area
16 FLT Charging Area 79 m² PIR PANEL 60MM RH GYPSUM Concrete with dry shake topping
17 Transformer Station 15 m² PIR PANEL 60MM RH GYPSUM Concrete with dry shake topping
18 RAMP 171 m² STEEL PANEL NONE Concrete floor finishing
EXTERIOR
19 STAIR 1 4 m² STEEL PANEL NONE Concrete floor finishing
EXTERIOR
20 STAIR 2 3 m² STEEL PANEL NONE Concrete floor finishing
EXTERIOR
Grand total 7046m2

Table 6 - Cold Storage Warehouse Finishing Datasheet

[Link].1 COLD STORAGE WAREHOUSE OFFICES

Photo 76 - Cold Storage Warehouse Offices Layout

Rooms Material Datasheet

 Walls
To this building will be considered block works of 15 and 20cm, plaster and painted. To the toilets will
be cover with ceramic tiles 30x30 full height.

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 137 / 162
  Floors
The floor will be having a porcelain tiles 60x60cm to interior and restrooms will be having ceramic tiles
30x30cm.

 Ceiling
To the toilets areas the ceiling will be a drywall water resistant. For the rest will be Armstrong type
60x120cm.

 Roof
The roof Panel will be made of PIR insulated with a steel cover.

 Doors and windows

All the doors for exterior will be metallic and to the interior will be wooden doors. The windows will be
double glazed.

 Finishing data sheet

750 - COLD STORAGE WAREHOUSE OFFICES
Number Name Area Wall Finish Ceiling Finish Floor Finish
1 CORRIDOR 40 m² Plaster and Paint ARMSTRONG TILES 600X1200 PORCELAIN TILES 600X600
2 OFFICE 4 14 m² Plaster and Paint ARMSTRONG TILES 600X1200 PORCELAIN TILES 600X600
3 OFFICE 3 13 m² Plaster and Paint ARMSTRONG TILES 600X1200 PORCELAIN TILES 600X600
4 STAIR 10 m² Plaster and Paint ARMSTRONG TILES 600X1200 PORCELAIN TILES 600X600
5 OFFICE 2 13 m² Plaster and Paint ARMSTRONG TILES 600X1200 PORCELAIN TILES 600X600
6 OFFICE 1 13 m² Plaster and Paint ARMSTRONG TILES 600X1200 PORCELAIN TILES 600X600
7 HVAC 41 m² Plaster and Paint NONE SCREED CEMENT
8 RESTROOM 39 m² Ceramic tiles 300X300 full height RH GYPSUM PANEL CERAMIC TILES NON SLIP 300X300
9 CANTEEN 53 m² Plaster and Paint ARMSTRONG TILES 600X1200 PORCELAIN TILES 600X600
10 KITCHENETTE 24 m² Ceramic tiles 300X300 full height ARMSTRONG TILES 600X1200 PORCELAIN TILES 600X600
11 OFFICE 5 19 m² Plaster and Paint ARMSTRONG TILES 600X1200 PORCELAIN TILES 600X600
12 TOILET 3 m² Ceramic tiles 300X300 full height RH GYPSUM PANEL CERAMIC TILES NON SLIP 300X300
13 ARCHIVE 4 m² Plaster and Paint ARMSTRONG TILES 600X1200 CERAMIC TILES NON SLIP 300X300
14 OFFICE 6 26 m² Plaster and Paint ARMSTRONG TILES 600X1200 PORCELAIN TILES 600X600
15 ARCHIVE 6 m² Plaster and Paint ARMSTRONG TILES 600X1200 CERAMIC TILES NON SLIP 300X300
16 TOILET 3 m² Ceramic tiles 300X300 full height RH GYPSUM PANEL CERAMIC TILES NON SLIP 300X300
17 ARCHIVE 15 m² Plaster and Paint ARMSTRONG TILES 600X1200 CERAMIC TILES NON SLIP 300X300
18 TOILET 3 m² Ceramic tiles 300X300 full height RH GYPSUM PANEL CERAMIC TILES NON SLIP 300X300
19 ARCHIVE 6 m² Plaster and Paint NONE CERAMIC TILES NON SLIP 300X300
20 OFFICE 7 35 m² Plaster and Paint ARMSTRONG TILES 600X1200 PORCELAIN TILES 600X600
21 CELLAR 91 m² Plaster and Paint NONE CERAMIC TILES NON SLIP 300X300
22 OFFICE 8 25 m² Plaster and Paint ARMSTRONG TILES 600X1200 PORCELAIN TILES 600X600
23 TOILET 3 m² Ceramic tiles 300X300 full height ARMSTRONG TILES 600X1200 CERAMIC TILES NON SLIP 300X300
24 ARCHIVE 4 m² Plaster and Paint ARMSTRONG TILES 600X1200 CERAMIC TILES NON SLIP 300X300
25 CORRIDOR 31 m² Plaster and Paint ARMSTRONG TILES 600X1200 PORCELAIN TILES 600X600
26 STAIR RISE 10 m² Plaster and Paint NONE RISER
27 ENTRANCE STAIR 9 m² External Plaster and Paint NONE CONCRETE FINISH
28 RAMP 6 m² External Plaster and Paint NONE CONCRETE FINISH
MACHINE
29 6 m² External Plaster and Paint NONE CONCRETE FINISH
TERRACE
Grand total 559m2

740 - Gate complex – Troubleshooting building

Number Name Area Wall Finish Ceiling Finish Floor Finish
1 OFFICE 35 m² PLASTER AND PAINT ARMSTRONG TILES 60X120 PORCELAIN TILES 60X60
2 HALL TOILET 4 m² PLASTER AND PAINT ARMSTRONG TILES 60X120 PORCELAIN TILES 60X60
3 TOILET 1 3 m² CERAMIC TILES 30X30 RH GYPSUM CERAMIC TILES NON SLIP 30X30
4 TOILET 2 2 m² CERAMIC TILES 30X30 RH GYPSUM CERAMIC TILES NON SLIP 30X30
5 DISABLE TOILET 4 m² CERAMIC TILES 30X30 RH GYPSUM CERAMIC TILES NON SLIP 30X30
6 TOILET 3 3 m² CERAMIC TILES 30X30 RH GYPSUM CERAMIC TILES NON SLIP 30X30
7 WAITING AREA 54 m² PLASTER AND PAINT ARMSTRONG TILES 60X120 PORCELAIN TILES 60X60
Grand total 105 m²

Table 7 - Cold Storage Warehouse Offices Finishing Datasheet

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 138 / 162
[Link] Main Substation

Photo 77 - Main Substation Layout

Rooms Material Datasheet

 Walls
For the perimeter walls 15 cm blocks will be considered, except the transformer room,
this will be concrete walls of 25cm (included steel reinforcement)

 Floors
The floor will be made of concrete slab, and a dry shake topping.
The openings of trench will be closed with a metallic grating, and a galvanized manhole cover.
The Control room, UPS/battery room and Metering room, will be finished with antistatic
epoxic paint flooring and raised floor over.

 Roof
The roof slab will be finished with an insulated coating.

 Doors and windows

All the doors for this building will be metallic
The windows will be made with mesh in the transformer’s rooms

 Finishing data sheet

630-Main Substation
Number Name Area Wall Finish Ceiling Finish Floor Finish
1 TMS1-69-1 80 m² PLASTER AND PAINT NONE Concrete with dry shake topping
2 TMS1-69-2 80 m² PLASTER AND PAINT NONE Concrete with dry shake topping
3 MS-69-2 58 m² PLASTER AND PAINT NONE Concrete with dry shake topping
4 SWITCHGEAR ROOM 3 123 m² PLASTER AND PAINT NONE Concrete with dry shake topping
5 LOW VOLTAGE ROOM 39 m² PLASTER AND PAINT NONE Concrete with dry shake topping
6 TMS1-13-2 11 m² PLASTER AND PAINT NONE Concrete with dry shake topping
7 TMS1-13-1 11 m² PLASTER AND PAINT NONE Concrete with dry shake topping
8 SWITCHGEAR ROOM 2 123 m² PLASTER AND PAINT NONE Concrete with dry shake topping
9 SWITCHGEAR ROOM 1 124 m² PLASTER AND PAINT NONE Concrete with dry shake topping
10 MS-69-1 58 m² PLASTER AND PAINT NONE Concrete with dry shake topping
11 CONTROL ROOM 34 m² PLASTER AND PAINT NONE Epoxic paint with raise floor
12 UPS ROOM 12 m² PLASTER AND PAINT NONE Epoxic paint with raise floor
13 METERING ROOM 17 m² PLASTER AND PAINT NONE Concrete with dry shake topping
Grand total 768 m²

Table 8 - Main Substation Finishing Datasheet

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 139 / 162
[Link] Reefer E-RTG Substation

Photo 78 - Reefer E-RTG Substation Layout

Rooms Material Datasheet

 Walls
For the perimeter walls 15 cm blocks will be considered, except the transformer room,
this will be concrete walls of 25cm (included steel reinforcement)

 Floors
The floor will be made of concrete slab, and a dry shake topping.
The openings of trench will be closed with a metallic grating, and a galvanized manhole cover.

 Roof
The roof slab will be finished with an insulated coating.

 Doors and windows

All the doors for this building will be metallic
The windows will be made with mesh in the transformers rooms

 Finishing data sheet

Table 9 - Reefer E-RTG Substation Finishing Datasheet

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 140 / 162
[Link] Troubleshooting Building

Photo 79 - Troubleshooting Building Layout

Rooms Material Datasheet

 Walls
To this building will be considered steel panel of exterior with a purlin of reinforcement, and to the
interior drywall plaster and painted with Rockwool.
To the toilets will be cover with ceramic tiles 30x30 full height.
 Floors
The floor will be having a porcelain tiles 60x60cm to interior and restrooms will be have ceramic tiles
30x30cm.

 Ceiling
To the toilets areas the ceiling will be a drywall water resistant. The rest, will be Armstrong type
60x120cm.

 Roof
The roof Panel will be made of PIR insulated with a steel cover.

 Doors and windows

All the doors for exterior will be metallic and to the interior will be wooden doors. The windows will be
double glazed.

 Finishing data sheet

740 - Gate complex – Troubleshooting building
Number Name Area Wall Finish Ceiling Finish Floor Finish
1 OFFICE 35 m² PLASTER AND PAINT ARMSTRONG TILES 60X120 PORCELAIN TILES 60X60
2 HALL TOILET 4 m² PLASTER AND PAINT ARMSTRONG TILES 60X120 PORCELAIN TILES 60X60
3 TOILET 1 3 m² CERAMIC TILES 30X30 RH GYPSUM CERAMIC TILES NON SLIP 30X30
4 TOILET 2 2 m² CERAMIC TILES 30X30 RH GYPSUM CERAMIC TILES NON SLIP 30X30
5 DISABLE TOILET 4 m² CERAMIC TILES 30X30 RH GYPSUM CERAMIC TILES NON SLIP 30X30
6 TOILET 3 3 m² CERAMIC TILES 30X30 RH GYPSUM CERAMIC TILES NON SLIP 30X30
7 WAITING AREA 54 m² PLASTER AND PAINT ARMSTRONG TILES 60X120 PORCELAIN TILES 60X60
Grand total 105 m²

Table 10 - Troubleshooting Building Finishing Datasheet

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 141 / 162
4.9.2. Common Procedures

[Link] Formwork and Stripping

The scope of this procedure covers the following elements: footings, beams, walls, columns, slab of
foundation and mezzanine, reinforced walls.

Join Venture, will apply the appropriate methods for the formwork and stripping, protecting the life of
people, selecting the materials per the application, it should be made of metal or impermeable plywood
to give the shape of the structure, using qualified manual labor for this type of work, use of mechanical
equipment if necessary to meet the needs of the employer.

[Link].1 PROCEDURE

The formwork must be properly braced or tied together, so that they retain their position and shape.
The forms and their supports must be designed in such a way that they do not damage the previously
constructed structure. The design of the formwork must consider the following factors:

(a) Speed and method of concrete placement;

(b) Construction loads, including vertical, horizontal and impact loads;

(c) Special requirements for formwork for the construction of shells, folded slabs, domes,
Architectural concrete or other types of similar elements.

Join venture, previously to the casting, will deliver the design of formwork structural calculation for
approval by the Engineer

The installation of the formwork will be done with the support of surveying equipment to ensure its
location and alignment and leveling both vertical and horizontal.

It will be verified and approved that the formwork is positioned correctly, according to the designs, and
must be firmly fixed in such a way that they do not suffer displacements during emptying or allow the
leakage of grout.

The formwork will be installed before each emptying, respecting the guidelines provided in the plans,
and will be fixed in such a way that they do not move during the casting of concrete.

• In any case, the Contractor must submit all the necessary information about the structure, and
they will be as follows:
• Sequence of concrete placement, as a critical factor
• The location and order of assembly and removal of the props for composite construction
• The dimension of the camber necessary for slabs or other structural elements in order to
compensate for the deflection of the structure. The camber builds measurements that are
achieved should be made at the level of the panel after the initial setting and before removing
the supports of the formwork.
• Locations and details of architectural concrete. When the architectural details are to be cast in
the structural concrete, they must be indicated or referred to in the structural plans since they
can have a key role in the design of the formwork.

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 142 / 162
 • Clamps or steel tensioners that pass through the concrete on one side of the formwork to the
opposite side, will be treated in a special way to prevent corrosion with a mixture composed of
polymer and protective corrosion inhibitor of environmental climatic agents.

Important: However, it is advisable to use an alternative method to this with prior approval of the
Engineer.

• The formwork must be designed for a minimum live load of horizontal projection design.

The design load for both combined loads, living and dead must be the minimum design if powered cars
are used. Windings and struts should be designed to withstand all horizontal loads, such as wind, cable
tension, inclined supports, concrete discharge, and starting and stopping equipment. Wind loads or
other windbreaks attached to the formwork must be considered in addition to the loads already
mentioned. The horizontal load shall not be less than that of the floor edge design, or 2% of the total
dead load in the formwork, distributed as a uniform load per lineal meter of the edge of the slab,
whichever is greater.

• For the removal of the formwork from the other parts of the structures, the following minimum
terms shall be required:

- Walls and columns (2) two days

- Slabs (14) fourteen days

Or as directed by the Engineer, in any case the formwork should be sprayed with a accepted stripping
helper to avoid any crack on the element. The supports of the formwork and the struts should not be
removed from the beams, floors and walls, until these elements have sufficient strength to support their
own weight and any load superimposed

• The life time of the formwork will depend of the material, but in any case will be permit
formworks with visible bends, crack or any defect that could carry on defects on the element or
a fatality risk for the personal on site.

Materials:

• MDP plywood
• Steel boards

Personnel:

• Superintendent
• Site engineer (yard)
• Site engineer
• Quality control manager
• Health & safety manager
• Worker
• Equipment operator

Equipment and tools:

• Mechanical jacks
• Clamps
• Hands tools
• Exterior corner bezels

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 143 / 162
 • GPS base/total station
• Scaffolding

[Link] Cast in Place Concrete (Foundations, Columns, Beams and Slabs).

This procedure applies to all cast in place concrete works carried on the project, development like a
general method of construction. If is necessary, the Contractor will development a specific construction
method.

[Link].1 PROCEDURE

• Prior to any work that involve cast in place concrete the Contractor should verify the tie of the
bars and construction joints have been retightened, dowels, bucks, sleeves, hangers, pipes,
conduits, anchor bolts, and any other fixtures required to be embedded in concrete shall be
placed and adequately anchored, dimensions of formwork and shoring a clamping of the
formwork will be double checked.
• The weather condition must be checked and in hot weather according to ACI 318- chapter
26.5.5 and in any case do not place concrete during rainstorms or high velocity winds or when
rain or high winds are forecast.
• Construction and expansion Joints shall be constructed where and as indicated on the
Drawings; the construction joints must be clean and free of sawdust, chips, and other debris
after forms are built and immediately before concrete or grout placement.
• When the placement consists of several layers, concrete delivery should be scheduled so that
each layer is placed while the preceding one is still plastic to avoid cold joints. If the underlying
layer has stiffened just beyond the point where it can be penetrated by the vibrator, bond can
still be obtained by thoroughly and systematically vibrating the new concrete into contact with
the previously placed concrete; however, an unavoidable joint line will show on the surface
when the form is removed." ACI's Guide for Consolidation of Concrete (ACI 309R-87)
• According to good construction practice, in any case drop concrete freely into place from height
greater than 1.60 meters will be permitted and horizontal layers should not exceed 600 mm in
depth and bring up evenly in all parts or forms.
• After concrete placement begins, continue concrete placement without significant interruption.
Plan and implement precautions to prevent any delay, between layers being placed, from
exceeding 20 minutes. If concrete is to be placed over previously placed concrete and more
than 20 minutes has elapsed, spread layer of cement grout not less than 1/2 inch in thickness
nor more than 1 inch in thickness over surface before placing additional concrete
• In any circumstance is allowed add any chemical material that not where specified on the
concrete design to change or improve the status of the material on site.
• All curing process should comply with Employer Requirements and ACI 318- 14 chapter 26.5.3
curing concrete.
• If any crack (not superficial) will be detected, the Contractor must development a method
statement to repair the crack properly, the Employer should be informed and notified of the
procedure adopted.

Materials:

CONCRETE (the design should be specified by each element)

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 144 / 162
Personnel:

• Superintendent
• Site engineer (yard)
• Site engineer
• Quality control manager
• Health & safety manager
• Worker
• Equipment operator

Equipment and tools:

• Batching plant
• Concrete mixer truck
• Concrete pump
• Hand tools
• Plug-in vibratory rod

Test:

Tests shall comply with ASTM C 31 - Standard Practice for Making and Curing Concrete Test
Specimens in the Field, C 39 - Standard Test Method for Compressive Strength of Cylindrical Concrete
Specimens and other applicable standards.

[Link] Rebar Works

The scope of this construction method is proposed for all works of the project that are according with
the activity.

Procedure:

• Prior to any work start, each bar must have compiled this characteristics:
- All material use in this activity shall be from an approved manufacturer.
- All reinforcing steel shall be free from grease, oil or other harmful material that affect adhesion
of concrete to the steel. In case bars get dirty or rusty, shall be cleaned and prepared by
brushing with wire brush or with chemicals.
- Steel reinforcement shall be stored in suitable dry conditions to prevent damage, surface
contamination and excessive oxidation. Steel bars shall be stored in a storage area designed
according the conditions of each working area; additionally, must be classified according similar
dimensions or elements. Bars would be safely stored on wooden blocks to avoid dirt and rust.
- Depending on the diameter or quantity of rebar works, cut bars manually (Manual Cutter) or
mechanically (Steel rebar cutting machine, metal cut-off saw or angle grinder) at REBAR
workshop.
- The cut bars will proceed to be bended (depending on the diameter) manually or mechanically,
in any case the schedule bar and drawings must clearly indicated dimensions and bends.

Materials:

• Rebar Fy 4200 Kg/cm2

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 145 / 162
Personnel:

• Superintendent
• Site engineer (yard)
• Site engineer
• Quality control manager
• Health & safety manager
• Worker
• Equipment operator

Equipment and tools:

• Rebar cutter/bender
• Hand rebar bender
• Angle grinder
• Rebar work bench
• Metal cutting chop saw
• Forklift
• Hand tools

[Link] Steel Works Installation

This procedure applies to all steel works installation of the project; this documents has been
development like a general method of construction. If is necessary, the Contractor will development a
specific construction method.

Procedure: General consideration for excavation works

• The elements to be assembled will be stored as far as possible in the same place of the
assembly area, so it is necessary to define a place for their correct storage in order to avoid
risks for people and the environment. Join venture will assign the place of storage, trying as far
as possible, that is close to the place of assembly in order to minimize the transport and
movement of trucks inside the work.
• In any case the loading or unloading of elements will be done with the use of a crane, and its
capacity will be determinate by the weight of the element to be moved, the angle and high of
the lifting
• The supervisor must inspect that the equipment and tools are in optimum condition, prior to the
execution of the work. Personnel should use PPE according to the recommendations given by
supervisor in charge
• All the elements that can be pre-assembled on floor must be assembled before to be lifted.
• The area of lifting should be signaled and must be free of any obstacle.
• Before to any lifting all the sling, rope or chains should be inspected.
• Immediately after the element will be on position should be tie or assured to a stable base or
structural element.

Materials: Non-applicable

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 146 / 162
Personnel:

• Superintendent
• Site engineer (yard)
• Site engineer
• Quality control manager
• Health & safety manager
• Worker
• Equipment operator

Equipment and tools:

• Crane
• Slings, rope or chains
• Hand tools
• Mechanical jacks

[Link] Masonry Works

[Link].1 CONCRETE BLOCKWORKS 0.15M, 0.20M AND 0.25M.

The scope of this construction method is proposed for all works of the project that are according with
the activity.

Procedure

Preliminary considerations Concrete

The concrete preparation, concrete supplier, cast in place, curing etc. will be carried out according to
the respective method of concrete.

Admixtures

Admixtures, chemical components or alike will be mixed according to the manufacturer and previously
approved the material.

Concrete mix used for blocks

This material shall be pre-designed to give a minimum crushing strength of 50 Kg/cm2. Concrete shall
be mixed in the mechanical mixer.

Curing and Drying of blocks shall be continuously moist for at least 14 days. Cured blocks shall be
allowed to dry for a period of 4 weeks before being used for allowing their initial shrinkage before they
are laid in the wall.

Blocks

All specifications of solid concrete blocks, including specifications for actual dimensions, tolerances,
sizes, shapes and webs, grades of blocks etc. shall conform to NTE INEN 3066.

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 147 / 162
All blocks shall be sound and free of cracks or other defects. For exposed construction, face or faces
shall be free of chips or other imperfections, and the overall dimensions of the blocks shall be in
accordance to tolerance as specified.

Methods on site

Before starting the block works should be slightly moistened to avoid absorption of water from mortar
some minutes previously to install.

Joints shall not be bigger than 8 mm and will be perfectly horizontal and vertical. Joints shall be raked
10 mm deep while mortar is wet.

The following measures should be taken like recommendation to prevent formation of cracks:

a) While curing, the block masonry should be lightly sprinkled with water and not made excessively
wet.

b) Expansion joints shall be provided in walls exceeding 30 m in length.

c) Reinforcement should be provided in the bed joints in block work, one course above and below
windows and one course above doors, in order to distribute the shrinkage/ temperature stresses
occurring at the corners of openings more uniformly throughout the walls.

d) A reinforced to masonry will be made by concrete column variation of 75mm to 150 mm thick
and width equal to block masonry thickness according reinforcement specification.

Mortar

Mortar for masonry shall be prepared in accordance with NTE INEN 2518. The mix proportions shall be
1:6 for 200 mm or thicker walls and 1:4 for thinner walls. In preparing the cement mortar, the
components shall first be mixed thoroughly in dry condition. Water shall then be added and mixing
continued to give a uniform mix of the required consistency. The prepared mortar shall be used within
30 minutes of mixing.

The aggregate shall be according to NTE INEN 2536

Curing of masonry

Masonry work as it progresses will be well watered/cured on both faces for at least 10 days after
completion. All green work shall be protected from rain by suitable coverings using plastic membranes.

Materials:

• Cement
• Concrete
• Blocks 15cm, 20cm and 25cm
• Water
• Plastic membrane

Personnel:

• Superintendent
• Site engineer (yard)
• Site engineer

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 148 / 162
 • Quality control manager
• Health & safety manager
• Worker
• Equipment operator

Equipment and tools:

• Spirit level
• Wooden/Aluminum straight edge 3 m long
• Mason Square
• Line and pins
• Plumb rule
• Boning rods
• Trowels
• Spades
• Mortar pan
• Circular Saw

[Link].2 CONCRETE PLASTER – INTERIOR AND EXTERIOR.

The scope of this construction method is proposed for all works of the project that are according with
the activity.

Procedure

Internal Plastering on surfaces of Brick and Concrete

Surface where plastering is to be done should be cleaned.

Level pegs on walls will be fixed with reference to the off lines to brick walls set out in floors. (Using
center plumb bob and nylon thread).

All the brick walls will be watered before pasting mortar on walls.

First coat mortar filling up to 15 mm will be applied on surfaces where required mortar thickness exceeds
25mm.

Vertical joint of structural columns / walls & brick walls will be treated by fixing 200mm width mesh with
wire nails / concrete nails by centering the mesh to the vertical wall joint.

All the embedded service lines and provisions (Conduits, Boxes and etc.) will be completed on brick
walls and check with the MEP drawings.

Joints between walls and beams will be formed up to a maximum of 20mm and will be sealed using 30
minutes’ fire rated flexible filler.

Internal plastering on surfaces of concrete columns, beams & walls which are aligned with surfaces of
brick walls will be plastered and other concrete surfaces will be finished with cement base easy plaster.

External Wall Plastering

Alignment and fixing level pegs on external wall surfaces will be done using the surveying instrument /
center plumb bobs.

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 149 / 162
Projections on the wall surfaces will be chipped off and cleaned after completing the level pegs on walls.

First coat mortar filling up to 15 mm will be applied on surfaces where required mortar thickness exceed
25mm.

Cement paste on concrete surfaces will be applied to improve the bonding of plaster to the concrete
surfaces.

Maximum width of 20mm horizontal grooves between walls and beams will be formed by cutting using
grinders with diamond wheels after plastering the wall surface. This groove will be filled with approved
weather sealant.

External wall plaster will be finished with rough surface.

1:10 slope at the external side of the window sill will be formed while plastering the window reveals.

Materials:

• Standardized Cement mortar (Approved by Employer)

• Water
• Stucco
• Sealer (Approved by Employer)

Personnel:

• Superintendent
• Site engineer (yard)
• Site engineer
• Quality control manager
• Health & safety manager
• Worker
• Equipment operator

Equipment and tools:

• Wooden/Aluminum straight edge 3 m long

• Meter steel tape
• Line and pin strings
• Plumb
• Trowels
• Metallic pallet
• Mechanic beater

[Link] FINISHINGS

[Link].1 PLASTER AND PAINT

The scope of this construction method is proposed for all works of the project that are according with
the activity.

Procedure: Preliminary considerations

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 150 / 162
Remove any hardware material none related to the painting works, if not possible (like glass screens,
exterior cladded panels or railings already fixed), cover/protect the surfaces with plastic sheets to
prevent from splatter.

The floor must be covered with a 1.20-meter width plastic sheet from the wall base. The surface area
must be even and smooth. Sandpaper is used to remove blemishes, imperfections and loose particles.
Prior the painting works, a sealer must have been applied on the walls.

Procedure

Paint preparation: mix water with paint in a 1:4 relations (satin paint and elastomeric paint), homogenize
with a clean spatula for walls until complete mixture.

This information is according to the paint supplier to be submitted for approval.

Will be applied the paint on a brush and trace the upper, lower, and lateral borders, including wall
intersections.

The upper border of the painting area must surpass the ceiling level by 10 centimeters.

For walls with skirting, the lower border of the painting area must settle about 5 centimeters above the
encounter with the floor.

To cover the windows and door’s frames from splatter, should be used painting tape and newsprint
paper.

To the paint works, will be used a plush or fabric paint roller and will start painting from the top to the
bottom of the wall. A paint brush could be used likewise.

For exterior walls, the painting works must start from the upper floor to the last.

For working at height, fixed and movable scaffolding would be erected according the area requirements.

For interior walls, a second coat of paint would be applied 3-4 hours after the first coat, using the same
method described above.

2 coats of paint are recommended to provide great coverage, resistance and a washable surface.

For exterior walls, a second coat of paint would be applied 8-10 hours after the first coat, using the
same method described above.

2-3 coats of paint are recommended to provide great elasticity, durability and a waterproof surface.

Total curing last 7 days.

Materials:

• Satin Paint
• Elastomeric Paint

Personnel:

• Painter
• Painter Assistant
• Work resident

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 151 / 162
 • HSE Supervisor
• QAQC Supervisor

Equipment and tools:

• Grit sandpaper
• Natural bristles paint brush
• Plush or fabric paint roller
• Painting tape
• Newsprint paper
• Minor Hand Tools

[Link].2 CERAMIC AND PORCELAIN TILES.

The scope of this construction method is proposed for all works of the project that are according with
the activity.

Procedure: Surface Preparation

All surfaces to received tile shall be structurally sound clean, dry and free from oil and all foreign matters.

Surfaces to receive tile shall be plumb, horizontal level or at the slope as specified and true with square
corners.

Prior to placing of tile the concrete surface shall be kept thoroughly wet.

Mixing

Mixing and applications of Adhesive and grouting shall be complied with manufacture’s procedure and
recommendations.

Wall Tile

The wall to receive tiles shall be finished with the approved plaster.

The plastering to the wall surfaces must be fully cured and free from any contamination, dust and crack
before commencing the wall tile works.

Setting out shall be done as per approved shop drawings.

The surveyor shall mark the finished floor level on the wall of the room.

Porcelain tile shall be soaked in water and it should be removed 20 minutes before use.

Wall tile fixing shall start from the fixed strip level.

Approved adhesive materials shall be applied to the wall as continuous and the wall tiles are fixed to
the adhesive with twisting/sliding action to give the finished bed thickness not more than 3mm.

Tile shall be correctly positioned in both directions by using 2mm plastic spacers to achieve even joints.

The tile shall be fixed in a way to get solid bedding and adhesion over the whole of the tile background.

Excessive adhesive material shall be removed with trowel without disturbing tiles. The cut tiles and the
tiles on the sides of sanitary fittings and fixings shall be properly cut and laid in a neat manner.

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 152 / 162
The fixed tile shall be left for minimum of 24 hours to cure before grouting or according the technical
instructions of the adhesive material.

Before start grouting, all spacers should be removed and ensure that there is no damages.

Simultaneously the tile shall be cleaned with the dry cloth to give a aesthetic look. The grouting mixing
and application shall be followed as per manufacturer’s data sheet/recommendations.

Floor Tile Installation

In interior finishing works, all tiles shall only be set and laid after the fixing of window and door frames
and trims, stop rails, electrical, plumbing installations as well as the application of plaster unless
otherwise specified.

For wet area only the approved water proofing system shall be installed.

Carry out a 24 hours’ water test for water tight purpose prior to start with tile activity for wet area only.

The surveyor shall mark the required level of the bedding screed /protection screed to the specified
thickness and in true alignment and horizontally or to slope as specified as per the approved drawings.

Setting out shall be done as per approved layout drawings. Joints shall be true to line, truly horizontal,
continuous and without steps.

For wet and dry area, ceramic tile shall be fixed by approved Tile adhesive.

Ceramic tile shall be soaked in water and it should be removed 20 minutes before use. Adhesive shall
be applied on working area not more than one square meter at a time or as per manufacturer’s
recommendations/procedure.

Tile shall then be laid on the adhesive layer with a twisting motion ensuring good contact between tile
and adhesive bed. For this purpose, the adhesive manufacturer’s instructions should be followed strictly
to achieve the 100% mortar coverage.

Tile shall be correctly positioned in both directions by using 2mm plastic spacers in order to
accommodate the difference between wall and floor tiles as per approved drawings.

The tile shall be neatly cut to a close fit where the necessary at abutments, around the outlets, pipes
and the like.

Particular care will be taken in ‘Wet’ areas to prevent low spots that may promote water pooling the
tolerance in the overall level shall not be more than5mm from required level.

Localized variation in level for nominally flat floor shall be max of + or – 3mm, when tested by 3meters
straight edge.

Excessive adhesive shall be removed with trowel before the material has set. The fixed tile shall be left
for minimum of 24 hours to cure before grouting.

Materials:

• Water
• Ceramic/porcelain tiles
• Adhesive and grouting

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 153 / 162
Personnel:

• Superintendent
• Site engineer (yard)
• Site engineer
• Quality control manager
• Health & safety manager
• Worker
• Equipment operator

Equipment and tools:

• Tape measure
• Framing square
• Marker
• Buckets
• Tile trowel
• Rubber mallet
• Sponges
• Tile spacers 2mm
• Gloves
• Safety glasses
• Tile cutter
• Grout float
• Spirit level
• Mechanical mixer

[Link] Metallic Carpentry

[Link].1 COLD CHAMBER CONSTRUCTION

The scope of this construction method is proposed for all works of the project that are according with
the activity.

Procedure: *Insulate PIR coating are installed before the concrete flooring filled

After cured the flooring finish, floor angles are fitted on the base to the required dimension of the cold
room.

Wall panels installation

Wall panels are installed on the fixed floor angles, will be erected the first panel on the floor angle, start
to end.

A thin layer of sealing compound will be applied on the joining face of the panels. Will be join the corner
of panel with wall panel by capping external and aluminum angle internal.

This process is the same to the whole wall.

Finished, will be applied sealing compound in the joining face of the panels.

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 154 / 162
Ceiling panels installation

Ceiling panels are installed top the rest on the top edges of the wall panels.

A thin layer of sealing compound will be applied on the outer plate seam of the ceiling panels, which is
to be positioned on the farthest end of the wall panels and suspension rods and top hat.

This process is the same to the whole ceiling.

Proceed with the next panel and apply the sealing compound in the same way as before, against the
wall panels as well as against the ceiling panels are installed. Finished, will be applied sealing
compound in the joining face of the panels.

Silicon sealants are filled at the joints of panels to ensure leak proof wall, ceiling surface.

Doors installation

Insulated doors as per the approved drawings will be fitted in the cut out of the wall panel and located
as per requirement and storage opening convenience.

PVC curtain will be hang from the top of the door to avoid air infiltration.

Materials:

• Insulated panel
• Bolts and cover
• Accessories
• Insulated doors
• Insulation flooring

Personnel:

• Superintendent
• Site engineer (yard)
• Site engineer
• Quality control manager
• Health & safety manager
• Worker
• Equipment operator

Equipment and tools:

• Drill
• Reciprocating saw
• Pressure plier
• Shear
• Rubber mallet
• Spatula
• Level ruler and plumb
• Chalk line kit
• Silicone gun

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 155 / 162
 [Link].2 PIR THERMIC INSULATIONS PANELS AND PVC SHEET
INSTALLATION FOR WATERPROOFING CONCRETE SLABS

The scope of this construction method is proposed for all works of the project that are according with
the activity.

Procedure: Surfaces Preparation

Surfaces must be cleaned and free of any leftovers or debris from construction works. Rain sewers are
to be displaced in the locations, quantities and specified diameters of the project. Levels and spilled
concrete falling into the sewers will be within the approved amount by the project and the construction
company through their respective delegates

THERMIC INSULATION PANELS INSTALLATION

The panels must have a paper protection on one of its sides, which will be in contact with the PVC sheet
and so, avoid direct contact between the two materials.

Thickness selected will be according to the drawings specifications.

The distribution of the panels on top of the concrete slabs will be done in an interleaved position, in the
same way it is done in a masonry wall.

The panels will be aligned and assured by mechanic fixings with nails, fixing plug, and washers.

At least fixings will be done in each 1m x 2m panel (one in each corner of the paper and three in the
center).

Depending on the installer judgment and weather conditions at the moment of installation, the number
of fixings may increase.

The depth of perforation in the concrete slab will be 2” maximum done by a 5/16” in diameter drill bit.
The panels must be cut according to the shape of the slab, walls, construction details as equipment´s
baseline, skylights, sewers, etc.

Remaining pieces may be used as long as they have at least one mechanical fixing to ensure the
stability to the slab. Mechanical fixings guarantee the stability of the panels during the installation and
following protection with the PVC sheet.

PVC SARNAFILL SHEET INSTALLATION

The installation will be done directly over the PIR panels on the side with the protective paper properly
fixed to the concrete slab. The cuts can be done with scissors or blade. When working on details on
vertical surfaces, the installation will be done directly over the concrete or walls of the plastered
masonry.

All the chops that are to be joined with each other must be done by an overlapping of at least 5cm wide,
pointing at the direction of the flow of water that will run over them in the case of rain. For that, an
approved heat-sealing gun type Liester 110v will be used at the temperature that the manufacturer
states and with any accessories listed in the technical specifications.

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 156 / 162
Materials:

• PIR panel
• Bolts with fisher plug
• Expansion bolts
• Nails
• Silicon
• PVC membrane
• Aluminum profiles

Personnel:

• Superintendent
• Site engineer (yard)
• Site engineer
• Quality control manager
• Health & safety manager
• Worker
• Equipment operator

Equipment and tools

• Power-driver
• Circular saw
• Drill
• Silicon gun
• Leister heater gun machine

[Link].3 METALLIC WALL CLADDING

The scope of this construction method is proposed for all works of the project that are according with
the activity.

Procedure: Surfaces Preparation

Surfaces must be cleaned and free of any leftovers or debris from construction works. Rain sewers are
to be displaced in the locations, quantities and specified diameters of the project. Levels and spilled
concrete falling into the sewers will be within the approved amount by the project and the construction
company through their respective delegates.

PLACING PANELS ON WALLS AS FOLLOWS

Install omegas horizontally on walls as support of panels. Install panels in place according shop
drawings.

Doors/Windows cut panel according drawings and manufacturer´s indications and install flashings to
guarantee esthetic finishes.

Panels should be installed according to installation shop drawings.

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 157 / 162
After overlapping panels fixers are going to be installed to keep panels altogether. At the moment of the
installation of the panels, panels will be supported to masonry of buildings, lift to place by hand or
mechanical equipment (Telehandler or ManLift) and fastened to the supporting metallic structure.

WALL PANEL INSTALLATION SEQUENCE

Removal of lower protective film panel Cleaning

Stacking in 5 or 10 groups.

Set panels, workers and equipment accordingly to the activity.

Materials:

• Wall panels.
• Accessories.

Personnel:

• Superintendent
• Site engineer (yard)
• Site engineer
• Quality control manager
• Health & safety manager
• Worker
• Equipment operator

Equipment and tools:

• Telehandler / Manlift.
• Hand tools.
• Scaffolding.

[Link].4 METALLIC ROOF, RIDGE AND GUTTER.

The scope of this construction method is proposed for all works of the project that are according with
the activity.

Procedure: Placing Panels on Roof

Panel installation should normally be started considering the opposite sense wind direction, so that the
overlap is in the direction of the wind.

Before uploading the packs of panels on top of the structure, freestanding scaffolding towers or ladders
used as a methodology will be installed so that workers have easy access, using their respective
harnesses with a lifeline. Workers can climb by means of a telehandler or stairs complying with safety
regulations.

Panels should be installed according to installation shop drawings.

A ridge cap will be installed where both panels meet at the ridge of the structure. Once finished one
side of the roof, repeat over installation process.

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 158 / 162
Panels must be placed and secured by overlapping vertically to the length of each side of the roof
(complete rows) individually or simultaneously.

After overlapping panels fixers are going to be installed to keep panels altogether.

At the moment of the installation of the panels, a worker will be located at the far end of a telehandler
and at the other end the people who will secure and join the panels with their respective harness and
life leash thus protecting the security.

When installing the panels on the other side of the roof, the same safety procedure will be followed,
thus avoiding occupational accidents.

Cuts shall be done with special scissors tool; never use grinder. Pencils should never be used to mark
cutting lines because coal (pencil or any variety) accelerates the normal process of oxidation of the
material.

Ridge: The correct installation and proper use of Cumber, avoid common problems such as leaks,
aesthetics, entry of insects, etc. When installed you should always be careful to overlap them a
minimum of 10cm. fixing to the sheets must always be done by self-tapping bolts. In the case of
meetings of 3 or more cumbers, associations must be as airtight as possible; the use of silicone for
sealing the joints is indispensable.

Gutter: The sections of the guttering are proceeded to align them on the floor with a levelling line, then
in each union they are secured with stick screws and silicon is placed. It is important that at each joint
of the gutters, there is an overlap of 5 cm.

It is recommended to make stretches no larger than 10 meters in order to be able to lift with the Platform
Lift and place them on previously installed structure, preferably that the joints are in the beam that
serves as support. Each connection shell be secured with screws and waterproofed with silicone.

Once all the sections of gutters have been hoisted, the lid is placed on each end and with a small grinder
the cuts are made for the downpipes. The gutters are adjusted on each support with an angle, which
will be secured to the structure of the gutter support by self-drilling screws and / or hilt ½ nails,
depending on the ease of doing the job.

To give the slope to the guttering, which is not more than 1 cm in the whole length, shims will be placed
in each support. Shims are permanent and will be used to keep levelled the gutter. Shims will be made
out of galvanized-steel sheets from 3mm up to 12mm and placed on mooring beams of gutter.

Materials:

• Panels.
• Accessories.
• Electro welded beams
• Laminated angles
• Cold formed purlin
• Extras

Personnel:

• Superintendent
• Site engineer (yard)
• Site engineer

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 159 / 162
 • Quality control manager
• Health & safety manager
• Worker
• Equipment operator

Equipment and tools:

• 35 Ton Crane.
• Telehandler / Manlift.
• Hand tools.
• Scaffolding.

[Link] Carpentry

[Link].1 WOODEN DOORS

The contractor shall submit shop drawings and/or samples of each type of doors, windows, louvers,
ventilators and other aluminum and alternative work, to the Engineer for his approval.

Procedure

All wood door shall be veneered finish with polyurethane coating to manufacturer’s specification.

Doors installation Layout

First, the reconfirmation of measures in the work is carried out, then proceeds to send the
measurements to the factory for the production of the door leaves and the leaves that will be installed
in the gaps of all the buildings of the work.

Installations of wooden frames

The first thing that is done is all the gaps in the doors is to color the wooden frame and then install the
sheet of each according to the corresponding code according to plans the codes.

Final details

After all the doors are installed in the gaps of the doors, proceed to place the door leaf with its
accessories that are hinged plates and kick doors and lacquer the doors and door leaves again if they
have any failure

Materials:

• MDF RH
• Polyurethane coating
• Bolts with Fisher plug
• Expansion bolts
• Nails
• Hex bolt
• Aluminum "F" profile
• Catalyzed lacquer

Personnel:

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 160 / 162
 • Superintendent
• Site engineer (yard)
• Site engineer
• Quality control manager
• Health & safety manager
• Worker
• Equipment operator

Equipment and tools:

• Screwdriver
• Circular saw
• Grinder
• Emery
• Silicone gun

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 161 / 162
APPENDIX – TESTING AND MONITORING PLAN

GENERAL ASPECTS
4.2.1 l) Arrangements and Construction Methods Statements – rev A 162 / 162
 TESTING AND MONITORING PLAN

[Link].20 FTO-CAL-04 V1

Puerto Bolivar Port Expansion - EPC

PROJECT: UPDATED DATE:
Container Terminal Development - Phase 1
ACTIVITY: REVISION:

INSPECTION POINTS
FEATURES METHODS RISKS
RESPONSIBLE
NAME OF THE

CLIENT´S
PRODUCT

PROCESS
PROCESS / REFERENCE CRITICAL
No. ASSESMENTS
OPERATION DOCUMENTS FEATURE SIZE AND SAMPLING PRELIMINARY
FEATURES SPECIFICATIONS TOLERANCE TECHNIQUES / EQUIPMENT REGISTER MITIGATION
DESCRIPTION FRECUENCY ASSESMENTS
MEASURES IMPLEMENTATION DECISIÓN MAKING

Measures to be evaluated
during the inspection stage
BS 6187 Security of the near existing Existing stability of the and definition of the
1 DEMOLITIONS PS X N.A. None Visual Inspection N.A. N.A. Property status report PPC JV PBO JV PBO & EMPLOYER
Construction plans. structures structures demolition method
Personnel experience in
demolition work

According to acceptance
Draft arrangement indicated Accuracy of measuring
PS X Tides criteria defined in Dredging Measure Tide Gauge monthly Tide Report Calibrated Equipment PIC JV PBO JV PBO
in construction plans equipment
methodology

Topography
Indicated in construction During horizontal Accuracy of measuring
PS X Position Control 0.5 m Measure Equipment topographical data Calibrated Equipment PIC JV PBO JV PBO
plans positioning equipment
(Total Station)

Great tidal differences Make Tidal Compensation

Required dredging level Digital: 3d drawing in
Construction's Plans, Bathymetry before and after Bathymetry Before and after dredging in
PS X indicated in Construction 0.5 m Measure Autocad 2015 PPC JV PBO JV PBO & EMPLOYER
dredgin methology and dredging Equipment monthly periods Measurement equipment Calibrated equipment and
Plans Physical: Signed Plan
BF1842-0400-1004 Volume pressure 2 periodic checks
2 DREDGING IV - ER Part 2 - 2782019
numeral 7
25 m in longitudinal
Accuracy of measuring
direction and at 10 m Calibrated Equipment
Soil Sampling for Indicated in dredging Indicated in dredging Sampling soil equipment
PS X Samplings intervals in transverse Laboratory report PIC JV PBO JV PBO
Improvement methology methology equipment
direction with respect to the Material Replacement
Material does not comply
docking line

Required dredging level Digital: 3d drawing in

Bathymetry Before and after dredging in Topography and bathymetry
PS X Dredging indicated in Construction 300 mm Measure Autocad 2015 Overburden excavation PPC JV PBO JV PBO & EMPLOYER
Equipment monthly periods controls
Plans Physical: Signed Plan

Topography Filled with 15/20 grade

According to construction Indicated in dredging During the excavation and
PS X Overburden excavation Measure Equipment Topographical data Topographic Control concrete or granular PPC JV PBO JV PBO
BF1842-0400-1004 Volume plans methology at the end
(Total Station) material
4 EXCAVATION IV - ER Part 2 - 2782019
numeral 8 Trench and Cable Bottom Densimeter and sand
PP X 95% of the modified proctor Larger than specified Measure each 40 m Laboratory report preliminary tests re-consolidate PPC JV PBO JV PBO
Bottom Compaction sustitution method

PP Liquid Limit Menor o igual 65%

PP Plastic Limit Menor o igual 35%

Cleanless
Free of vegetation, peat,
PP organic matter, according to Applicable regulations
standard and type of filling

chlorides, expressed as
BF1842-0400-1004 Volume chloride ions - 0.6% by for each type of filling
IV - ER Part 2 - 2782019 X weight; Samplings Laboraty equipments Laboratory report Preliminary tests Designer evaluation PIC JV PBO JV PBO
PP Durability test Chlorides and Sulfates selected
numeral 9 • sulfates, expressed as
sulfate ions: 0.6% by
weight.

According to the contract

PP Physical properties Granulometry
signed

BF1842-0400-1004 Volume
Flexometer,
IV - ER Part 2 - 2782019 PP X Compaction Thickness not more than 300 mm Measure Per layer Topographical data Higher thicknesses Topographic control PPC JV PBO JV PBO
Topography
numeral 9

BF1842-0400-1004 Volume Cover the material in case

5 FILLED IV - ER Part 2 - 2782019 of rain
numeral 9 PC X Compaction Moisture content 1% y -3%, Measure Laboraty equipments Per working days Laboratory report preliminary tests PPC JV PBO JV PBO
Let dry in case of higher
BS 1377: Pt 4 - 1990. humidity

BF1842-0400-1004 Volume
Adjust designs according to
IV - ER Part 2 - 2782019 According to the type of By test area
greater than or equal to the Preliminary compaction preliminary tests
numeral 9 PC X Densidad filling, defined in Measure Laboraty equipments variations in the material Laboratory report PPC JV PBO JV PBO
specified tests
constructive methodology 3 tests each 2500 m2
Additional tests
BS 1377: Pt 4 - 1990.
Pág. 1 de 10
 TESTING AND MONITORING PLAN

[Link].20 FTO-CAL-04 V1

Puerto Bolivar Port Expansion - EPC

PROJECT: UPDATED DATE:
Container Terminal Development - Phase 1
ACTIVITY: REVISION:

INSPECTION POINTS
FEATURES METHODS RISKS
RESPONSIBLE
NAME OF THE

CLIENT´S
PRODUCT

PROCESS
PROCESS / REFERENCE CRITICAL
No. ASSESMENTS
OPERATION DOCUMENTS FEATURE SIZE AND SAMPLING PRELIMINARY
FEATURES SPECIFICATIONS TOLERANCE TECHNIQUES / EQUIPMENT REGISTER MITIGATION
DESCRIPTION FRECUENCY ASSESMENTS
MEASURES IMPLEMENTATION DECISIÓN MAKING

without clay lumps retained

BF1842-0400-1004 Volume
in a 75 mm sieve or for each type of filling
IV - ER Part 2 - 2782019 PC X Fillings around the pipe No tolerance Measure Laboraty equipments Laboratory report preliminary tests Designer evaluation PPC JV PBO JV PBO
rocks and stones retained in selected
numeral 9
a 38 mm sieve.

BF1842-0400-1004 Volume
greater than or equal to the
IV - ER Part 2 - 2782019 PC X Field CBR According desings Measure Laboraty equipments Agreement with the client Laboratory report preliminary tests Designer evaluation PPC JV PBO JV PBO & EMPLOYER
specified
numeral 9

BF1842-0400-1004 Volume
CPT and SPT to under greater than or equal to the
IV - ER Part 2 - 2782019 PC X According desings Measure Laboraty equipments Agreement with the client Laboratory report preliminary tests Designer evaluation PPC JV PBO JV PBO & EMPLOYER
water filled specified
numeral 9

"free of laminations and weak

cleavage planes and will be of
such
BF1842-0400-1004 Volume character that will resist
Selection of the most
IV - ER Part 2 - 2782019 PC X Source Physical Characteristics disintegration or erosion by Visual Inspection N.A. By source or beta Report Sources study PIC JV PBO JV PBO
the action of air, water,
appropriate source
numeral 10
humidification and drying and
impact due to the action of
waves. "

"Manual on the use of rocks EUCL - high class extreme

in coastal and coastal limit - 97% -100%
engineering ", Construction Specific weights of rock UCL - upper class limit - 70% -
random sample comprising
industry sizes ELCL, LCL, UCL 100% Selection of the most
PC X Clasification Sampling Laboraty equipments at least 20 individual rocks Laboratory report Sources study PIC JV PBO JV PBO
Special Publication 83 of and EUCL in order of LCL upper class limit - 0% - appropriate source
10% per source
the Research and increasing size
Information Association ELCL low end extreme limit -
0% -2%
(CIRIA),

random sample comprising

Selection of the most
PS X Training process Natural No tolerance Sampling N.A. at least 20 individual rocks Sources study PIC JV PBO JV PBO
appropriate source
per source

random sample comprising

Sedimentary, igneous a Selection of the most
PS X Petrographic No tolerance Sampling Laboraty equipments at least 20 individual rocks Sources study PIC JV PBO JV PBO
metamorphic appropriate source
per source

random sample comprising

Selection of the most
PS X Density 2.65 Mg/cu.m. Min 2.65 Mg/cu.m. Sampling Laboraty equipments at least 20 individual rocks Sources study PIC JV PBO JV PBO
appropriate source
per source

random sample comprising

Max 20% mayor Selection of the most
PS X Form Thickness Length Ratio Sampling Laboraty equipments at least 20 individual rocks Sources study PIC JV PBO JV PBO
de 3: 1 appropriate source
per source

"Max 5% per number random sample comprising

Selection of the most
PS X Fractured Faces Broken or flat surfaces with less than 50% Sampling Laboraty equipments at least 20 individual rocks Sources study PIC JV PBO JV PBO
crushed or broken "
appropriate source
per source

random sample comprising

Amount of absorption water Max 1.5% Selection of the most
PS X Absortion Sampling Laboraty equipments at least 20 individual rocks Sources study PIC JV PBO JV PBO
being submerged mass cattle appropriate source
per source
6 GRAVEL FILLINGS BS EN 13383. Laboratory report
random sample comprising
Minimum average value of Selection of the most
PS X Breaking Strength Compression test Sampling Laboraty equipments at least 20 individual rocks Sources study PIC JV PBO JV PBO
60 Mpa appropriate source
per source

random sample comprising

Max micro-Deval Selection of the most
PS X Hardness Wear - Abrasion Resistance Sampling Laboraty equipments at least 20 individual rocks Sources study PIC JV PBO JV PBO
coeff: of 30 appropriate source
per source

random sample comprising

Strength (resistance to Selection of the most
PS X Durability test Maximum loss of 25% of mass Sampling Laboraty equipments at least 20 individual rocks Sources study PIC JV PBO JV PBO
magnesium and sulfates) appropriate source
per source

Pág. 2 de 10
 TESTING AND MONITORING PLAN

[Link].20 FTO-CAL-04 V1

Puerto Bolivar Port Expansion - EPC

PROJECT: UPDATED DATE:
Container Terminal Development - Phase 1
ACTIVITY: REVISION:

INSPECTION POINTS
FEATURES METHODS RISKS
RESPONSIBLE
NAME OF THE

CLIENT´S
PRODUCT

PROCESS
PROCESS / REFERENCE CRITICAL
No. ASSESMENTS
OPERATION DOCUMENTS FEATURE SIZE AND SAMPLING PRELIMINARY
FEATURES SPECIFICATIONS TOLERANCE TECHNIQUES / EQUIPMENT REGISTER MITIGATION
DESCRIPTION FRECUENCY ASSESMENTS
MEASURES IMPLEMENTATION DECISIÓN MAKING

random sample comprising

Non significant fissures with Selection of the most
PS X Integrity presence of fissures Sampling Laboraty equipments at least 20 individual rocks Sources study PIC JV PBO JV PBO
1.5 m drop appropriate source
per source

random sample comprising

No significant sign of Selection of the most
PS X Sonnenbrand Basalt Decay Sampling Laboraty equipments at least 20 individual rocks Sources study PIC JV PBO JV PBO
decomposition appropriate source
per source

random sample comprising

Selection of the most
PS X Color Natural Color Not required Sampling N.A. at least 20 individual rocks Sources study PIC JV PBO JV PBO
appropriate source
per source

BF1842-0400-1004 Volume Topography

According to construction No more than 10 m in the Topographic Portfolio Evaluation of areas and
IV - ER Part 2 - 2782019 PC X Placement it does not require Measure Equipment and Topographic control PIC JV PBO JV PBO
plans measurement profile Survey Report volumes
numeral 10 Probing Equipment

BF1842-0400-1004 Volume
puncture resistance,
IV - ER Part 2 - 2782019 PC X Geotextile as a filter layer Indicate in design Indicate in design N.A. Per production lot Quality certificate Poor material quality Material tests PPC JV PBO JV PBO & EMPLOYER
durability in seawater
numeral 10

Maximum silt content

By Beta and / or type of
dispersed in the granular no more than 5% Sampling
material or every 20,000 m3
material
Selection of the most
PP X Cleanless Laboraty equipments Laboratory report Sources study PIC JV PBO JV PBO
appropriate source
By Beta and / or type of
materia orgnica 0% Sampling
material or every 20,000 m3

"Dry <30% By Beta and / or type of Selection of the most

X Aggregate Aggregate Impact Value Sampling Laboraty equipments Laboratory report Sources study PIC JV PBO JV PBO
Saturated <40% " material or every 20,000 m3 appropriate source
PP
BF1842-0400-1004 Volume Strength (resistance to By Beta and / or type of Selection of the most
X Durability Maximum loss of 30% of mass Sampling Laboraty equipments Laboratory report Sources study PIC JV PBO JV PBO
IV - ER Part 2 - 2782019 magnesium and sulfates) material or every 20,000 m3 appropriate source
numeral 11.5.3
Amount of absorption water By Beta and / or type of Selection of the most
BS 1377: Parte 2: 1990 PP X Absorption Max 6% Sampling Laboraty equipments Laboratory report Sources study PIC JV PBO JV PBO
being submerged material or every 20,000 m3 appropriate source
SOIL IMPROVEMENT
7
(FILLING MATERIAL) By Beta and / or type of Selection of the most
PP X Compaction Density > 2.3Mg / m 3 Sampling Laboraty equipments Laboratory report Sources study PIC JV PBO JV PBO
material or every 20,000 m3 appropriate source

By Beta and / or type of Selection of the most

PP X Cleanless Plastic Limit <6% Sampling Laboraty equipments Laboratory report Sources study PIC JV PBO JV PBO
material or every 20,000 m3 appropriate source

By Beta and / or type of Selection of the most

PP X Composition Gradation According with BS 1377 Sampling Laboraty equipments Laboratory report Sources study PIC JV PBO JV PBO
material or every 7,500 m3 appropriate source

AASHO T234 o T235, o BS By Beta and / or type of Selection of the most

PP X Internal angle of friction Proof of Cut According to AASHO T234 Sampling Laboraty equipments Laboratory report Sources study PIC JV PBO JV PBO
1377 material or every 20,000 m3 appropriate source

BS 1377: Parte 4: "According to BS 1377: Part 4: Selection of the most

PS X Compaction Density Field test Laboraty equipments One each 200 m2 Laboratory report Sources study PIC JV PBO JV PBO
1990, 1990 and preliminary studies " appropriate source

at least 250 m3 / year when

BF1842-0400-1004 Volume subjected to a Evaluation or comparison in
SOIL IMPROVEMENT Evaluation of similar drains
8 IV - ER Part 2 - 2782019 PS X Properties Load Capacity Side pressure of 300kN / m2 coditions similar to that of N.A. At the beginning Inspection report N.A. PIC JV PBO JV PBO
(VERTICAL DRAINAGE) and folded by 20% vertical work
already built
numeral 11.5.4
compression.

Blending rate, optimal soil Laboratory

PP X SOIL - CEMENT Design Laboratory stadies one for each type of mixture Design of soil-cement Materials studies optimal material selection PIC JV PBO JV PBO
moisture, proctor. equipments
BF1842-0400-1004 Volume
SOIL IMPROVEMENT
9 IV - ER Part 2 - 2782019
(MIXTURE)
numeral 11.6.5
Blending rate, optimal soil Laboratory
PP X Mixed with lime Design Laboratory stadies one for each type of mixture mixture design Materials studies optimal material selection PIC JV PBO JV PBO
moisture, proctor. equipments

Pág. 3 de 10
 TESTING AND MONITORING PLAN

[Link].20 FTO-CAL-04 V1

Puerto Bolivar Port Expansion - EPC

PROJECT: UPDATED DATE:
Container Terminal Development - Phase 1
ACTIVITY: REVISION:

INSPECTION POINTS
FEATURES METHODS RISKS
RESPONSIBLE
NAME OF THE

CLIENT´S
PRODUCT

PROCESS
PROCESS / REFERENCE CRITICAL
No. ASSESMENTS
OPERATION DOCUMENTS FEATURE SIZE AND SAMPLING PRELIMINARY
FEATURES SPECIFICATIONS TOLERANCE TECHNIQUES / EQUIPMENT REGISTER MITIGATION
DESCRIPTION FRECUENCY ASSESMENTS
MEASURES IMPLEMENTATION DECISIÓN MAKING

By Beta and / or type of Study of information Selection of the most

PP X Saturated Density Dry Surface > 2.600 kg / m 3 Sampling Laboratory equipment Laboratory report PIC JV PBO JV PBO
material or every 20,000 m3 sources appropriate source

By Beta and / or type of Study of information Selection of the most

PP X Absorption amount of water in weight <3% Sampling Laboratory equipment Laboratory report PIC JV PBO JV PBO
material or every 20,000 m4 sources appropriate source

By Beta and / or type of Study of information Selection of the most

PP X Cleanless Plastic Limit No plastic Sampling Laboratory equipment Laboratory report PIC JV PBO JV PBO
material or every 20,000 m5 sources appropriate source

By Beta and / or type of Study of information Selection of the most

PP X sulphate concentration <0.6% Sampling Laboratory equipment Laboratory report PIC JV PBO JV PBO
material or every 20,000 m6 sources appropriate source

Durability Mass loss after 5N or cycles

Solidity (resistance to <12% for By Beta and / or type of Study of information Selection of the most
PP X Sampling Laboratory equipment Laboratory report PIC JV PBO JV PBO
magnesium and sulfates) sodium sulfate and <18% for material or every 20,000 m7 sources appropriate source
magnesium sulphate
BF1842-0400-1004 Volume
IV - ER Part 2 - 2782019 By Beta and / or type of Study of information Selection of the most
SOIL IMPROVEMENT PP X Peeling index <40 Sampling Laboratory equipment Laboratory report PIC JV PBO JV PBO
10 numeral 11.7.8 material or every 20,000 m8 sources appropriate source
(STONE COLUMNS)
BS 812 Pt.2: 1995 Unconfined compression By Beta and / or type of Study of information Selection of the most
PP X Hardness > 100Mpa Sampling Laboratory equipment Laboratory report PIC JV PBO JV PBO
resistance material or every 20,000 m9 sources appropriate source
By Beta and / or type of
Study of information Selection of the most
PP X abrasion <15% Sampling Laboratory equipment material or every 20,000 Laboratory report PIC JV PBO JV PBO
sources appropriate source
m10
According to design According to Design
PP X # Strokes Direct measurement N.A. PIC JV PBO JV PBO
parameters parameters

Volume of material According to design According to Design Control record of

PP X Direct measurement N.A. Designer Evaluation PIC JV PBO JV PBO
incorporated parameters parameters dynamic replecement

According to design Tape measure, According to Design

increase number of
PP X Penetration Percentage Direct measurement renego on parameters PIC JV PBO JV PBO
Dynamic replecement parameters Topography parameters substitutions
design
Limit pressure report Another soil improvement
According to design According to Design
PP X Piesometric Module Direct measurement Piezometer and pieometric methodology PIC JV PBO JV PBO
parameters parameters
module
According to design According to Design
PP X Load - Deformation - Time Field test Plate test equipment Laboratory report PIC JV PBO JV PBO
parameters parameters

Dimensional Control
Geometry External dimension -1% to + 1%. Direct measurement Measuring Tape Each one Pipe Factory Inspection Evaluación Diseñador PIC JV PBO DESIGNER
Report

BF1842-0400-1004 Volume
IV - ER Part 2 - 2782019 Marking with the following:
numeral 12 PS X 1. Manufacturing number
2. Dimatro
BS 8004 Identification All PILES Visual Inspection N.A All piles Piles identification Pipe Factory Inspection Evaluación Diseñador PIC JV PBO JV PBO
3. Length
4. Marks every 250 mm in
the upper 3 m

According to BS 7668, BS EN
Visual Inspection N.A 10113-1, BS EN 10155, BS Quality certificate Pipe Factory Inspection Designer evaluation PIC JV PBO DESIGNER
BS 7668, BS EN 10113-1, EN 10210-1 (or Similar)
According to BS 7668, BS EN
Chemical and physical
BS EN 10155, BS EN PP X Materials 10113-1, BS EN 10155, BS
properties EN 10210-1 (or Similar)
10210-1 (o equivalente)
Sampling Laboratory Equipment 3 samples from each source Laboratory Reports Pipe Factory Inspection Designer Evaluation PIC JV PBO DESIGNER

Define the types of welding

Elongation with spot Procedure specification One for each type of
PP X N.A. N.A. N.A procedure that will be required for N.A. PIC JV PBO JV PBO
welding WSP welding for pile connection
joining piles

Development of WPS Welders are qualified

Elongation with spot De acuerdo a Especificación
AWS PP X Inspection UT Measure UT Equipment Each weld Inspection report Procedure Specification for according to WPS PIC JV PBO JV PBO
welding de Procedimiento WPS
the particular project procedure specification

11 PILES Development of WPS Welders are qualified

Elongation with spot De acuerdo a Especificación Dye penetrant test
PP X Dye penetrant test Visual Inspection Each weld Inspection report Procedure Specification for according to WPS PIC JV PBO JV PBO
welding de Procedimiento WPS equipment
the particular project procedure specification

Soil studies and driving

behavior of surrounding Hacer cumplir criterio o
PP X Driving Resisted / rejected Definir en criteriors de hincado Visual Inspection Driving Equipment Each pile Driving record PIC JV PBO DESIGNER
piles evaluación del diseñador
PDA tests

Pág. 4 de 10
 TESTING AND MONITORING PLAN

[Link].20 FTO-CAL-04 V1

Puerto Bolivar Port Expansion - EPC

PROJECT: UPDATED DATE:
Container Terminal Development - Phase 1
ACTIVITY: REVISION:

INSPECTION POINTS
FEATURES METHODS RISKS
RESPONSIBLE
NAME OF THE

CLIENT´S
PRODUCT

PROCESS
PROCESS / REFERENCE CRITICAL
No. ASSESMENTS
OPERATION DOCUMENTS FEATURE SIZE AND SAMPLING PRELIMINARY
FEATURES SPECIFICATIONS TOLERANCE TECHNIQUES / EQUIPMENT REGISTER MITIGATION
DESCRIPTION FRECUENCY ASSESMENTS
MEASURES IMPLEMENTATION DECISIÓN MAKING

The conditions of
positioning of the piles are CUSTOMER RELEASE
Theoretical location Topographic controls during
PP X Position ± 75 mm Topographic Control Automatic Level Each pile Driving record evaluated, help with PPC JV PBO DESIGNER APPROVAL (in case
according to plans installation
guidance to preserve the of default)
BF1842-0400-1004 Volume position
IV - ER Part 2 - 2782019
numeral 12
The conditions of
positioning of the piles are CUSTOMER RELEASE
BS 8004 1/75 Relacion de longitud en Spirit level and Topographic controls during
PP X Verticality Verticality Topographic Control Each pile Driving record evaluated, help with PPC JV PBO DESIGNER APPROVAL (in case
una de las caras flexometer installation
guidance to preserve the of default)
position

Random to Designer
PDA (Dynamic Load DESIGNER APPROVAL (in case
PP X Load capacity Dynamic Load Test Carga de Diseño Measure Dynamic Load Test Criteria (minimum 7% of the NA NA PPC JV PBO
Test) Record of default)
total piles)

BF1842-0400-1004 Volume CUSTOMER RELEASE

Prefabricated installation
IV - ER Part 2 - 2782019 PP X Pile Decapitated Pile Decapitated ± 15 mm Topographic Control Automatic Level Each pile Driving record Topographic Control PPC JV PBO DESIGNER APPROVAL (in case
adjustments
numeral 12 of default)

Compressive strenght
Compressive strenght C40/50 Type Sampling
equipment

min 400 Kg/m3

Content of cement Design N.A.
Max 450 Kg/m3

Water / cement ratio 0.38 Design N.A.

BF1842-0400-1004 Volume Thick: 10/20 o 4/20 Final concrete mix

IV - ER Part 2 - 2782019 according to BS EN 12620 design report, Preliminary tests and / or
CONCRETE OF MARINE Type of aggregate Sampling Laboratory Equipment Adjustments to JV PBO
12 numeral 13.2 PC X Minimum requirements Fine 0/4 (MP) a BS EN Preliminary tests includes laboratory review of concrete formula N.A. JV PBO
STRUCTURES 12620 Manufacturing Formulas THE CUSTOMER IS INFORMED
reports and quality materials
BS EN 12620 certificates
Maximum size added 20 mm Sampling Laboratory Equipment

Chlorides C10/20 Sampling Laboratory Equipment

settlement S3 Sampling Laboratory Equipment

Portland cement complying

with BS class EN197-1
Cementitous material Sampling Laboratory Equipment
High slag
cement to BS146: 2002

Compressive strenght
Compressive strenght C32/40 Type Sampling
equipment

min 370 Kg/m3

Content of cement Design N.A.
Max 425 Kg/m3

Water / cement ratio .045 Design N.A.

Thick: 10/20 o 4/20
according with BS EN
Type of aggregate 12620 Sampling Laboratory Equipment
BF1842-0400-1004 Volume Final concrete mix
Fine 0/4 (MP) to BS EN
IV - ER Part 2 - 2782019 design report, Preliminary tests and / or
CONCRETE IN OTHER 12620 Adjustments to JV PBO
13 numeral 13.2 PC X Minimum requirements Preliminary tests includes laboratory review of concrete formula N.A. JV PBO
STRUCTURES Manufacturing Formulas THE CUSTOMER IS INFORMED
reports and quality materials
Maximun size added 20 mm Sampling Laboratory Equipment
BS EN 12620 certificates

Chlorides C10/20 Sampling Laboratory Equipment

settlement S3 Sampling Laboratory Equipment

Portland cement complying

with BS class EN197-1
Cementitous material Sampling Laboratory Equipment
High slag
cement to BS146: 2002

Compressive strenght
Compressive strenght C32/40 Type Sampling
equipment

min 325 Kg/m3

Content of cement Design N.A.
Max 375 Kg/m3

Water / cement ratio 0.5 Design N.A.

Thick: 10/20 o 4/20

BF1842-0400-1004 Volume according to BS EN 12620 Final concrete mix
Type of aggregate Sampling Laboratory equipment
IV - ER Part 2 - 2782019 Fino 0/4 (MP) to BS EN design report, Preliminary tests and / or
NON REINFORCEMENT 12620 Adjustments to JV PBO
14 numeral 13.2 PC X Minimum requirements Preliminary tests includes laboratory review of concrete formula N.A. JV PBO
CONCRETE Manufacturing Formulas THE CUSTOMER IS INFORMED
reports and quality materials
Pág. 5 de 10
 TESTING AND MONITORING PLAN

[Link].20 FTO-CAL-04 V1

Puerto Bolivar Port Expansion - EPC

PROJECT: UPDATED DATE:
Container Terminal Development - Phase 1
ACTIVITY: REVISION:

INSPECTION POINTS
FEATURES METHODS RISKS
RESPONSIBLE
NAME OF THE

CLIENT´S
PRODUCT

PROCESS
PROCESS / REFERENCE CRITICAL
No. ASSESMENTS
OPERATION DOCUMENTS FEATURE SIZE AND SAMPLING PRELIMINARY
FEATURES SPECIFICATIONS TOLERANCE TECHNIQUES / EQUIPMENT REGISTER MITIGATION
DESCRIPTION FRECUENCY ASSESMENTS
MEASURES IMPLEMENTATION DECISIÓN MAKING

reports and quality materials

BS EN 12620 Maximun size added 20 mm Sampling Laboratory equipment certificates

Chlorides C10,20 Sampling Laboratory equipment

settlement S3 Sampling Laboratory equipment

Portland cement complying

with BS class EN197-1
Cementitous material Sampling Laboratory equipment
High slag
cement to BS146: 2002

Compressive strenght
Compressive strenght C28/35 TYPE Sampling
equipment

Content of cement Max 300 Kg/m3 Design N.A.

BF1842-0400-1004 Volume Water / cement ratio 0.55 Design N.A. Final concrete mix
IV - ER Part 2 - 2782019 design report, Preliminary tests and / or
Adjustments to JV PBO
15 PAV2 CONCRETE BS8500 numeral 13.2 PC X Minimum requirements Preliminary tests includes laboratory review of concrete formula N.A. JV PBO
magnesium solidity be MS Manufacturing Formulas THE CUSTOMER IS INFORMED
Type of aggregate Sampling Laboratory equipment reports and quality materials
18
BS EN 8500 certificates
Maximun size added 20 mm Sampling Laboratory equipment

Chlorides C10,20 Sampling Laboratory equipment

settlement S2 Sampling Laboratory equipment

BF1842-0400-1004 Volume soluble sulfate, chloride or

Evaluation of available
16 WATER FOR CONCRETE IV - ER Part 2 - 2782019 PS X Purity other chemical content, Drinking Water Sampling Laboratory Equipment By source Laboratory Record Select a suitable source N.A. JV PBO JV PBO
sources
numeral 13.7 sediment and pH value.

Experience of using each

BF1842-0400-1004 Volume type of additive in other
Chemical and physical According to BS EN 934
17 CONCRETE ADDITIVES IV - ER Part 2 - 2782019 PS X Minimum requirements Visual Inspection N.A. By type of additive Data Sheet projects. Check Due Dates N.A. JV PBO JV PBO
properties Part 2: 2001
numeral 13.8.2
Additive in good condition

Inmersion By production batch Temperatures greater than

PP X Concrete temperature less than or equal to 32 °C Direct measurement Concreting control Rechazo del lote PIC JV PBO JV PBO
thermometer received 32 °C

Special healers
Temperature Curing Products,
High ambient temperatures Shadow, membranes,
By production batch that may affect the curing wetting
PS X Air temperature Less than 25 °C Direct measurement Thermometer Concreting control PIC JV PBO JV PBO
received and development of Night work or in the morning
concrete hours or any method of
curing according to ACI -
308-92
BF1842-0400-1004 Volume
RECEPTION OF THE
18 IV - ER Part 2 - 2782019
CONCRETE
numeral 13.9
The minimum average
resistance determined from
any group of 4" "test
results" "shall be: f cu + 3
Sampling according with BS One sample each 40 m3 or
PS X Compression resistance Compression resistance The minimum resistance Laboratory Equipment Laboratory report Preliminary concret tests Designer evaluation PIC JV PBO JV PBO
1881 by tipe of concrete
determined from any test
result "" is: f cu - 1.5

f what is the required

resistance in N / mm 2

Make an evaluation to
Chemical and physical According with BS, EC o Laboratory tests on the
PP X Properties Revision N.A. Each batch or draft receives Quality certificate select the most reliable PIC JV PBO JV PBO
BF1842-0400-1004 Volume properties ASTM material
suppliers
IV - ER Part 2 - 2782019
19 REINFORCING STEEL
numeral 13.16 y Normas
BS, EC o ASTM Chemical and physical According with BS, EC o Random sampling of the
PS X Properties Laboratory tests Laboratory equipment Laboratory report Breach of the material Lot Rejection N.A. JV PBO JV PBO
properties ASTM received bars

Pág. 6 de 10
 TESTING AND MONITORING PLAN

[Link].20 FTO-CAL-04 V1

Puerto Bolivar Port Expansion - EPC

PROJECT: UPDATED DATE:
Container Terminal Development - Phase 1
ACTIVITY: REVISION:

INSPECTION POINTS
FEATURES METHODS RISKS
RESPONSIBLE
NAME OF THE

CLIENT´S
PRODUCT

PROCESS
PROCESS / REFERENCE CRITICAL
No. ASSESMENTS
OPERATION DOCUMENTS FEATURE SIZE AND SAMPLING PRELIMINARY
FEATURES SPECIFICATIONS TOLERANCE TECHNIQUES / EQUIPMENT REGISTER MITIGATION
DESCRIPTION FRECUENCY ASSESMENTS
MEASURES IMPLEMENTATION DECISIÓN MAKING

Hasta 3 m ± 6 mm
3 a 4.5m ± 9 mm
Recepción de Inspeccion antes y durante
Lenght 4.5 a 6m ± 12 mm Medicion Flexometro Cada elemento Revisón de formaletas N.A. JV PBO JV PBO
Prefabricados fabricación
Adicional por cada 6m
subsiguientes ± 6 mm

Hasta 500 mm ± 3 mm
500 a 750 mm ± 5 mm
Adicional por cada 250 mm Recepción de Inspeccion antes y durante
Cross Section Medicion Flexometro Cada elemento Revisón de formaletas N.A. JV PBO JV PBO
subsiguientes ± 2 mm Prefabricados fabricación
Con una tolerancia máxima
de ± 15 mm

Hasta 3m ± 6 mm
Straightness or arc 3 a 6 m ± 9 mm
Recepción de Inspeccion antes y durante
(deviation from the 6 a 12 m ± 12 mm Medicion Flexometro Cada elemento Revisón de formaletas N.A. JV PBO JV PBO
Prefabricados fabricación
BF1842-0400-1004 Volume expected line) Adicional por cada 6m
IV - ER Part 2 - 2782019 PS X Manufacture subsiguientes ± 6 mm
numeral 13.20
Longitud de lados más
cortos
Recepción de Inspeccion antes y durante
Quadrature Hasta 1.2m= 3mm Medicion Flexometro Cada elemento Revisón de formaletas N.A. JV PBO JV PBO
Prefabricados fabricación
De 1.2m a 1.8m= 5mm
más de 1,8 m = 6mm

Hasta 600 mm de ancho y

hasta 6 m de largo 6mm
Recepción de Inspeccion antes y durante
Turn Medicion Flexometro Cada elemento Revisón de formaletas N.A. JV PBO JV PBO
Más de 600 mm de ancho y Prefabricados fabricación
para cualquier longitud.
12mm
Recepción de Inspeccion antes y durante
20 PREFABRICATED Flatness menor o igual a 5 mm Medicion Flexometro Cada elemento Revisón de formaletas N.A. JV PBO JV PBO
Prefabricados fabricación
Bolt Position and Recepción de Inspeccion antes y durante
± 6 mm Medicion Flexometro Cada elemento Revisón de formaletas N.A. JV PBO JV PBO
Accessories Prefabricados fabricación

No estar rajadas o
reparadas.
Sin bordes rotos si el
refuerzo está expuesto o
no.
BF1842-0400-1004 Volume
No deberá tener ningún Recepción de Inspeccion antes y durante Controles desde
IV - ER Part 2 - 2782019 PP X Acceptance Inspección visual N.A. Cada elemento PIC JV PBO JV PBO
refuerzo con cubierta. Prefabricados fabricación Fabricación
numeral 13.20.6
Acabado de acuerdo a
especificaciones de
referencia.
Recepción Cumplir tolerancas
dimensionales

-Tipo y número de referencia.

- Fecha de manufactura.
Número de formaleta
BF1842-0400-1004 Volume -Resultados de Resistencia.
Recepción de Inspeccion antes y durante Controles desde
IV - ER Part 2 - 2782019 PS X Brand and Registrations -Ubicación en las obras. Inspección visual N.A. Cada elemento PIC JV PBO JV PBO
- Método de curado y
Prefabricados fabricación Fabricación
numeral 13.20.8
duración.
- Certificados de Calidad de
Materiales

According to the final level Topographic Portfolio Prefabricated dimensional Adjustment in installation
Heights Measure topography equipment Each item Installed PIC JV PBO JV PBO
BF1842-0400-1004 Volume of the project Survey Report control dimensions
IV - ER Part 2 - 2782019 PS X Instalación
numeral 13.20.14 vertical front line exposed Topographic Portfolio Prefabricated dimensional
less than or equal to 5 mm Measure topography equipment Each item Installed Item setting N.A. JV PBO JV PBO
between adjacent units Survey Report control

Review by Designer, in
addition the chains must be
electrically welded and the
stud link chain complies
with Grade 30 Class 1 to
BS
Chemical and physical
6405 or equivalent
properties of materials Review and approval by Verification of compliance
approved. ""Review by Revision N.A. By lot delivered by supplier Quality certificate PIC JV PBO JV PBO
(coatings, fixings, chains designer with Design requirements
Designer, in addition the
and accessories)
chains must be electrically
welded and the stud link
chain complies with Grade
BF1842-0400-1004 Volume 30 Class 1 to BS
IV - ER Part 2 - 2782019 PS X Defensas 6405 or equivalent
numeral 15.7 approved.

Pág. 7 de 10
 TESTING AND MONITORING PLAN

[Link].20 FTO-CAL-04 V1

Puerto Bolivar Port Expansion - EPC

PROJECT: UPDATED DATE:
Container Terminal Development - Phase 1
ACTIVITY: REVISION:

INSPECTION POINTS
FEATURES METHODS RISKS
RESPONSIBLE
NAME OF THE

CLIENT´S
PRODUCT

PROCESS
PROCESS / REFERENCE CRITICAL
No. ASSESMENTS
OPERATION DOCUMENTS FEATURE SIZE AND SAMPLING PRELIMINARY
FEATURES SPECIFICATIONS TOLERANCE TECHNIQUES / EQUIPMENT REGISTER MITIGATION
DESCRIPTION FRECUENCY ASSESMENTS
MEASURES IMPLEMENTATION DECISIÓN MAKING

Density ISO 2781 Max

1.20g / cc
Polymer (rubber) ASTM
D6370 Min 45% Review and approval by Verification of compliance
Goma Revision N.A. By lot delivered by supplier Quality certificate PIC JV PBO JV PBO
Carbon black ASTM D6370 designer with Design requirements
Min 20%
Ash ASTM D297 Max 5%
Rubber fill ratio> 1.2

According to BS 6349: Review and approval by Verification of compliance

X 200 tons of SWL Revision N.A. By lot delivered by supplier Quality certificate PIC JV PBO JV PBO
BF1842-0400-1004 Volume Bean' bollards with Parte 4: Cl. 10.2.6 designer with Design requirements
IV - ER Part 2 - 2782019 PS standard 'D' double horn
numeral 15.8 base Tightening torque in According to manufacturer Bollard Installation Review and approval by Verification of compliance
INSTALACIONES Y X Equipment Adjustment Torque wrench Each bolt adjusted PIC JV PBO JV PBO
21 installation recommendations Record designer with Design requirements
ACCESORIOS
British Steel CES 2: 1987
Make an evaluation to
Crane Rails According with Laboratory tests on the
PS X Crane Rails Revision N.A Per lot received Quality certificate select the most reliable N.A.
fabricado en acero specifications material
suppliers
conforme a BS 11

Define the types of welding

WPS procedure One for each type of
N.A. N.A. N.A Procedure that will be required for rail N.A. PIC JV PBO JV PBO
specification welding for pile connection
welding
BF1842-0400-1004 Volume
IV - ER Part 2 - 2782019
numeral 15.14 Development of WPS Welders are qualified
According with the WSP
PP X Welding Rails UT Inspection Measure UT Equipment Each Weld Inspection report procedure specification for according to WPS PIC JV PBO JV PBO
procedure specification
the particular project procedure specification

Development of WPS Welders are qualified

According with the WSP Dye penetrant test
Dye penetrant test Visual Inspection Each Weld Inspection report procedure specification for according to WPS PIC JV PBO JV PBO
procedure specification equipment
the particular project procedure specification

Topography
H 5 mm of the level Welding installation Ensure installation surface Topographic controls before
Level Measure Equipment Per installed rail PIC JV PBO JV PBO
specified by the customer report level and during installation
Tape measure
Topography
Welding installation Ensure installation surface Topographic controls before
Pending 2 mm in any length of 2 m. Measure Equipment Per installed rail PIC JV PBO JV PBO
report level and during installation
Tape measure
BS 6651. PS X Rail installation
less than 5 mm from the
Topography
specified location and no Welding installation Topographic controls before
Rail line Measure Equipment Per installed rail Controls before installation PIC JV PBO JV PBO
more than 2 mm in any report and during installation
Tape measure
length of 2 m.

Welding installation Topographic controls before

Caliber ± 5 mm Measure Tape measure Random Controls before installation PIC JV PBO JV PBO
report and during installation

Granulometry According with ASTM C

Sampling Laboratory Equipment By Origin Laboratory report PIC JV PBO JV PBO
418
Make an evaluation to
Laboratory tests on the
PP X Sand Layer Plastic Limit NP Sampling Laboratory Equipment By Origin Laboratory report select the most reliable PIC JV PBO JV PBO
material
suppliers and sources
Sand equivalent Minimo 60% Sampling Laboratory Equipment By Origin Laboratory report PIC JV PBO JV PBO

PAVIMENTO EN Min. 5 MPa /promedio 5

22 ASTM C418 Per production lot of
ADOQUIN Breakage Module Test especimenes Sampling Laboratory Equipment Laboratory report PIC JV PBO JV PBO
maximum 10,000 units.
Min. 4.2 MPa / Unidad
Make an evaluation to
Laboratory tests on the
PP X Paving Stones select the most reliable
promedio 5 elementos ≤ 5% Per production lot of material
Absorption Sampling Laboratory Equipment Laboratory report suppliers and sources PIC JV PBO JV PBO
Individual ≤ 7% maximum 10,000 units.
Average 5 elements <= 23 Per production lot of
Lenght of track Sampling Laboratory Equipment Laboratory report PIC JV PBO JV PBO
mm maximum 10,000 units.

Gradation
Wear
Degradation
Mechanical strength
Stony Aggregates According with ASTM 6114 Sampling Laboratory Equipment By Origin Laboratory report PIC JV PBO JV PBO
Durability
Cleaning
Geometry
Adhesiveness Make an evaluation to
Laboratory tests on the
23 ASPHALT PAVEMENT ASTM 6114 PP X select the most reliable
material
suppliers and sources

According to ASTM 6114, it

is chosen according to the
Quality certificate and
Type of asphalt Selection climatic characteristics, type Revision Laboratory Equipment By Origin PIC JV PBO JV PBO
laboratory report
of layers and operating
conditions of the pavement

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 TESTING AND MONITORING PLAN

[Link].20 FTO-CAL-04 V1

Puerto Bolivar Port Expansion - EPC

PROJECT: UPDATED DATE:
Container Terminal Development - Phase 1
ACTIVITY: REVISION:

INSPECTION POINTS
FEATURES METHODS RISKS
RESPONSIBLE
NAME OF THE

CLIENT´S
PRODUCT

PROCESS
PROCESS / REFERENCE CRITICAL
No. ASSESMENTS
OPERATION DOCUMENTS FEATURE SIZE AND SAMPLING PRELIMINARY
FEATURES SPECIFICATIONS TOLERANCE TECHNIQUES / EQUIPMENT REGISTER MITIGATION
DESCRIPTION FRECUENCY ASSESMENTS
MEASURES IMPLEMENTATION DECISIÓN MAKING

Visual inspection;
• Verify integrity (reference
to drawings);
• Mechanical controls;
• Control circuit control;
Compliance with the
• Signal verification and
Factory Acceptance Pureba requirements of each Indicate in FAT / SAT Random sample of each of Development of FAT / SAT
PP X measurement; Inspection and monitoring FAT Certificate Verify evidence compliance PIC JV PBO JV PBO
(FAT) material and FAT SAT Test Test Protocol the components Protocols
• High voltage test;
Protocol
• Insulation measurement;
• Marks and signs;
• Checking the presence of
special, auxiliary tools, p.
Ex.

Visual inspection;
• Control circuit control
(including external
connections);
• Signal verification and
measurement;
• High voltage test;
• Insulation measurement;
• Contact resistance
SYSTEM AND measurement on the
BF1842-0400-1004 Volume contact surfaces of the Compliance with the
24 ELECTRICAL
IV - ER Part 3C - 2782019 Prueba de Aceptación en screwed connections, such requirements of each Indicate in FAT / SAT Random sample of each of Development of FAT / SAT
INSTALLATIONS PP X Inspection and monitoring SAT certificate Verify evidence compliance PIC JV PBO JV PBO
Sitio (SAT) as the busbar material and FAT SAT Test Test Protocol the components Protocols
sections; Protocol
• Marks and signs;
• Checking of special and
auxiliary tools;
• Interlocking test;
• Phase sequence;
• Configuration verification;
• Test of protection devices
(by means of current
injection in the primary
circuit).

The system is shown to

Indicate in FAT / SAT Development of FAT / SAT
PC X System Test In test protocol comply with the FAT / SAT Inspection and monitoring Whole System Service test record Verify evidence compliance PPC JV PBO JV PBO
Test Protocol Protocols
specifications and protocol

The system is shown to

Indicate in FAT / SAT Development of FAT / SAT
PC X Commissioning In test protocol comply with the FAT / SAT Inspection and monitoring Whole System Service test record Verify evidence compliance PPC JV PBO JV PBO
Test Protocol Protocols
specifications and protocol

The system is shown to

Indicate in FAT / SAT Development of FAT / SAT
PC X Performance Test In test protocol comply with the FAT / SAT Inspection and monitoring Whole System Service test record Verify evidence compliance PPC JV PBO JV PBO
Test Protocol Protocols
specifications and protocol

• SENSITIVE POINT (PS): Inspection point that may have an impact on the final result of the construction process but does not oblige to stop the activity, however its compliance or concession must be ensured by the decision maker.
• CRITICAL POINT (PC): Inspection point that does not require to stop the subsequent activity, however the control must ensure compliance with the specification and / or tolerance established.
• STOP POINT (PP): Inspection point that forces to stop the activity until the defined control has been executed and accepted according to the established specification and tolerance.
• CUSTOMER INSPECTION POINT (PIC): Point from where customer inspection is required
• CUSTOMER STOP POINT (PPC): Point from which release and / or approval by the client is required

NAME POSITION SIGNATURE

PREPARED BY EDGAR MATEUS QUALITY ENGINEER

REVIWED BY

APPROVED BY

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 TESTING AND MONITORING PLAN

[Link].20 FTO-CAL-04 V1

Puerto Bolivar Port Expansion - EPC

PROJECT: UPDATED DATE:
Container Terminal Development - Phase 1
ACTIVITY: REVISION:

INSPECTION POINTS
FEATURES METHODS RISKS
RESPONSIBLE
NAME OF THE

CLIENT´S
PRODUCT

PROCESS
PROCESS / REFERENCE CRITICAL
No. ASSESMENTS
OPERATION DOCUMENTS FEATURE SIZE AND SAMPLING PRELIMINARY
FEATURES SPECIFICATIONS TOLERANCE TECHNIQUES / EQUIPMENT REGISTER MITIGATION
DESCRIPTION FRECUENCY ASSESMENTS
MEASURES IMPLEMENTATION DECISIÓN MAKING

EXCHANGE CONTROL EXCHANGE CONTROL

DATE VARION EXCHANGE DATE VERSION EXCHANGE

DD/MM/AAAA 0 DD/MM/AAAA 6

DD/MM/AAAA 1 DD/MM/AAAA 7

DD/MM/AAAA 2 DD/MM/AAAA 8

DD/MM/AAAA 3 DD/MM/AAAA 9

DD/MM/AAAA 4 DD/MM/AAAA 10

DD/MM/AAAA 5 DD/MM/AAAA 11

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