METHODOLOGY
Erection At Cement mill Hopper Building
By
HAPBO PVT LTD
Site : RCCPL MUKUNTBAN
INDEX.
1. Objective
2. Purpose
3. Scope
4. Work Execution Process
5. Methodology
6. SAFETY MEASURES
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To ensure the management, erection and installation work on site are safe, correctly,
and complexly the contract specification
2. PURPOSE
The purpose of this method of statement is to establish a work sequence on how to
erect and installation of Hoppers(8 numbers of hoppers) will be implemented. The
statement includes work methodology and sequence of activities all in accordance with the
contract specification for plate & structural Erection work.
3. SCOPE
The following works, define the activities which will be carried out for implementation
the erection and installation ofHoppers:-
i. Transportation of Hoppers, Stools, Transition pieces & cylindrical portions to a
location near to the hopper building.
ii. Unloading, Arrangement, Storage and Protection of Materials.
iii. Checking & preparation of civil foundation for elevation matching.
iv. Chain block , slings, hydraulic jacks , de-shackles, wire rope slings , shall be
provided additionally for erection if needed
v. Erection of 8 numbers of Hoppers,
1. Erection of 2 Gypsum Hopper.
2. Erection of 2 Wet Fly Ash Hopper.
3. Erection of 2 Lime Stone Hopper
4. Erection of 2 clinker hoppers
vi. Erection of Equipments, Plate works &Structures.
vii. No-Load Trails.
4. WORK EXECUTION PROCESS.
a. Job Site Planning & Preparation .
Make sure there is space and firmed pathway for truck delivery, suitable crane
for operation. The suitable truck & crane capacity must be clarified .
The plan for unloading and materials storage on the site at a suitable and dry
location. Materials shall be stored in designated areas for each section and
clearly identified for their location as per planning.
The erection should be made in suitable Cranes/ Electrical Winch/ Chain Pulley
Block as per the weight of the preassemblies.
b. Receiving of material at site .
All delivery materials to the site shall be informed to the site manager/
engineer to have the plan for unloading. Upon arrival of materials at the
storage yard, the materials controller will match delivery notes and shall verify
the consignment.
Unloading can be done manually with80 MT and farana (14mt) Crane.
Spider bracings should be used for long steel components. Lifting slings of
nylon, cloth belts or wire rope slings with suitable SWL shall be used for
unloading the materials to minimize the damage. Using proper hook belts to
component with the right number of points and position so that the component
itself does not gets damaged or broken especially the coating/discolor.
All materials receipt at the site shall be visually inspected by site
supervisor/engineer for any damage after unloading. Any damage items shall
be taken immediately, if possible, to avoid any delay of erection.
c. Sequence of Erection .
Lifting plans as well as lifting dates are planned as per available conditions.
Materials are brought near the respective erection site using proper trailers,
etc.
Documentation of materials brought is completed.
Farana’s or cranes of proper capacity are used to unload material at site .
Selection of lifting materials for erection will depend on the available condition
of site as well as the engineer handling it.
While erection crane and farana will be used (not for tandem only for tailing)
Cranes (80 MT) will be taken into use as per the availability.
While tailing the material farana will not be allowed to march.
Chain blocks, ton buckles and hydraulic jacks are used for arresting the erected
components safely.
Trained personnel’s i.e. (engineers, rigging experts, fitters, welders, grinders,
gas cutters and safety officials etc) are selected for the job.
d. Factors affecting erection
The Erection at CEMENT MILL HOPPER Building can be erected in various ways which will
depend on the following key factors:-
Transportation of Fabricated / brought out items to the area.
The availability ofcivil foundation at hopper buildings.
The availability of Preassemblies and brought out items of hopper buildings
Site Condition.
The Experience level of erectors.
The individual job condition.
e. TOOLS & TACKLES
Chain block 1MT -05 no’s
Chain block 2MT -05 no’s
Chain block 3MT -08 no’s
Chain block 5MT -08 no’s
Chain block 10MT -08 no’s
De-shackles 17 MT- 10 no’s
De-shackles 8.5 MT- 10 no’s
De-shackles 4.5 MT- 10 no’s
De-shackles 3 MT- 06 no’s
Wire rope 32mm
Wire rope 25mm
Wire rope 20mm
Wire rope sling 32 mm 8 mtr- 04no’s
Wire rope sling 25 mm 8 mtr- 04no’s
Wire rope sling 25 mm 6 mtr- 04no’s
Wire rope sling 20 mm 6 mtr- 04no’s
Wire rope sling 25 mm 3 mtr- 04no’s
Wire rope sling 19 mm 6 mtr- 04no’s
Wire rope sling 19 mm 3 mtr- 06no’s
Wire rope sling 16 mm 6 mtr- 06 no’s
Wire rope sling 16 mm 3mtr- 06 no’s
Hydraulic jack :- 25 MT
Hydraulic jack :- 50 MT
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Erection of 8 Numbers of Hoppers, other plate works, Brought out items & Technological
Structures at Hopper Building.
1. Transportation of Fabricated / Brought out items to erection area .
Transportations of material is using by a trailer of 20 MT and 40 MT capacity and
crane (which is change by the weight of consignment usually can be done in 15 MT, 23MT
farana& 80MT cranes) to from store/ fabrication yard to the erection point near hopper
building.
2. Unloading
The fabricated/brought out items unloading planned by using 15-tonnes crane (crane
capacity varied by consignment weight). Before unloading materials out of trucks, the
platform or access road must be prepared properly for crane and trucks by term safely load.
And while unloading the items the area for unloading should be barricaded & only the
permitted worker should be enter the area for unloading and stacking the materials.
3. Arrangement.
To avoid materials being moved so much on the job site that might cause unexpected
damages of paint or discolor and shapes, they shall be unloaded and arranged close to the
designed erection point. The materials shall be stacked in location according to the
building/areas, should be near to the lifting position adjacent to the area to be erected.
Conditions of each job site, the materials arrangement plan may different based on
open clear area. The cone pieces and the stools pieces should be arranged close to their
civil foundation. Transition pieces of hoppers should be arranged to ensure easy to move.
All condition arrangement should be checked & mark as per erection plan before unloading
for the best unloading position.
4. Pre-Assemblies
The all brought out items shall be pre-assembled as per specified drawings.
5. Erection
The capacity of Crane / Electrical Winch / Chain pulley Block will be varying by the
weight schedules / assemblies are already done in ground level. Before starting the lifting
all lifting tools should be inspected by both safety officials and riggers. The lifting 1 swing
area will be barricaded to prevent unauthorized works or personnel into the area.
5.1 Erection 2 numbers Gypsum Hoppers.
Erection will be done in two parts of each hopper.
Marking and checking of elevation for the erection of stool.
Erection of Stool with cone piece attached (9 MT)
Erection of Cylindrical Portion (7.5 MT)
Complete both inside and outside welding and final painting.
Material will be erected over the elevation of (26.500mtr) and will be placed to their
actual elevation of (13.700mtr).
5.2 Erection 2 numbers Fly Ash Hoppers .
Erection will be done in two parts of each hopper.
Marking and checking of elevation for the erection of stool.
Erection of Stool with cone piece attached (9 MT)
Erection of Cylindrical Portion.( 7.5 MT)
Material will be erected over the elevation of (26.500mtr) and will be placed to their
actual elevation of (13.700mtr).
Complete both inside and outside wilding and final painting.
5.3 Erection2 numbers Lime Stone Hoppers .
Erection will be done in two parts of each hopper.
Marking and checking of elevation for the erection of stool.
Erection of Stool with cone piece attached.(10.5 MT)
Erection of Cylindrical Portion.( 7.5 MT)
Complete both inside and outside wilding and final painting.
Material will be erected over the elevation of (26.500mtr) and will be placed to their
actual elevation of (13.700mtr).
5.4 Erection of Clinker Hopper( of 600 MT Capacity).
Erection will be done in 5 parts.
Stool Erection: Dragging to the position with help of Crane &Electrical Winch /
Chain Pulley Block to the marked elevation.
After positioning the stool piece at the marked elevation of +17.600 mtr +1.000
mtr on a temporary stool & free the crane for erection of the transition piece.
Erection of two numbers of Hopper bottom Pieces and will be temporary placed to
the elevation of +7.100 mtr level by using 80MT crane. Then erected the transition
piece and Dragging to the position with help of Suitable crane and chain pulley
block after positioning the Clinker Hopper Stool piece on the temporary stool
pieces.
After completing the matching and welding of the Clinker Hopper Stool with
Transition pieces, then positing the two number of bottom pieces by using chain
pulley block (10 mt) and matching with Transition pieces lowered up to the
elevation mark of +17.600mtr.
After completion of fit up inside and outside welding will be done by using
scaffolding.
Erection of Cylindrical Part: By using Electrical Winch with 80Mt crane, positioning
the cylindrical portion by crane with supported by Electrical Winch and completes
the outside welding.
Erection of cylindrical pieces by 250 mt crane directly one lift from ground level to
the position. And complete the welding.
Fixing the chain blocks on civil floor by using wire rope and wire rope sling
(20mm,25mm and 32mm). Wire rope will be highlined(3&4 lacing).
All wire rope high line will be spliced and provide 3 clamp.
SAFTEY MEASURES
Safety helmet shall be provided which conform to Indian Standards (IS) and shall be worn
while on construction sites.
Industrial grade safety glasses with side shields meeting IS Standard IS 5983(1980) or
equivalent will be worn by all related personnel. This also applies to all persons wearing
prescription glasses. Additionally, protection may be necessary for various work activities
such as grinding, cutting, chipping, drilling, etc.
Gloves will be worn when handling material that may cut, terror burn hands. Gloves will be
in good condition and free of excessive oil or grime.
Safety belts/harnesses shall be worn a dosed when working at two-meter heights (or more),
where approved platforms, ladder so scaffolds not provided. Horizontal or vertical lifelines
will be provided and used when no tie-off points are provided; belts/harnesses shall be
worn properly. All fall protections equipment’s will be inspected for defects by the user
before each use. Defective o r q u e s t i o n a b l e equipment shall not be used.
All persons must report all injuries to their supervisors and obtain first aid (regardless of
severity) at the first aid facility.
Personnel (except electricians) assigned to work on around specific electrical jobs, will stay
clear of all electrical equipment utility proves safe by qualified electrical personnel.
UN-AUTHORISEDUSE: The unauthorized operation of any tool, equipment, switch, etc… is
strictly prohibited.
Personnel will not fabricate or use makeshift devices such as lifting, tools, etc.
Specialized tools/equipment are often necessary but will be meticulously designed and
tested by authorized engineering personnel be for use. The modification of tools/
equipment’s or the over-riding of safety devices will not be tolerated.
Running, practical jobs, etc, are prohibited .Fight in gas enough cause for immediate
dismissal. “Short cutting” or established safe practice surd liberate change-taking is strictly
prohibited.
Personnel must always ensure safe working positions. Never place yourself between objects
which could roll, shift, and fall or be displaced. Stay alert to conditions around you and all
times.
All tools and equipment’s, including motor vehicles, will always be operated in a safe and
prescribed manner. If anyone is unsure of the proper method of tool/ equipment use, he
must immediately inform his supervisor to receive proper direction.
Supervisors are responsible for strict compliance and enforcement of project and client
safety rules, regulations, and to ensure that workers are knowledgeable of requirements. All
personnel are required to follow instructions from their immediate supervisors. If
instructions are not clear or confusing, the employee has a responsibility to question to
supervisor and obtain clear instructions before commencement of work.
Please ensure co-operation and team work to complete construction projects in a safe,
efficient and time manner. All project personnel are expected to render complete co-
operation in the administration and enforcement of the project safety programmer.
The use of illegal drugs and alcohol is strictly prohibited and is cause for immediate removal
from the project site.
Disciplinary action will be taken against persons violating requirements. Serious infraction
and/ or repair offenders will be dealt with severely, up to and including permanent removal
for the project.
At fabrication yard minimum 2 fire extinguishers & 4 buckets of sand should be present all
the time.