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Kuwait National Petroleum Company

(K.S.C) Method Statement P6012MAB-000-51-1-M308


Clean Fuels Project For REV. OA, 22-Mar-2015
KNPC Contract No. CFP/EPC/0054-MAB1 CAST-IN-SITU BAY Page 2 of 18
PSCJV Job No. JI-2025

Record of Revisions

Rev. No. Page/Section Description

OA

List of Holds

Page/Section Description

MS-1146-025
Kuwait National Petroleum Company
(K.S.C) Method Statement P6012MAB-000-51-1-M308
Clean Fuels Project For REV. OA, 22-Mar-2015
KNPC Contract No. CFP/EPC/0054-MAB1 CAST-IN-SITU BAY Page 3 of 18
PSCJV Job No. JI-2025

TABLE OF CONTENTS

1.0 GENERAL 5

1.1 PURPOSE 5
1.2 ABBREVIATIONS 5
1.3 DETAILS OF THE PROJECT 5
1.4 DEFINITION 5

2.0 REFERENCES 6

3.0 LOCATION 6

4.0 EQUIPMENTS 6

5.0 RESOURCES 6

6.0 KEY PERSONNEL 7

7.0 PROCEDURE 7

7.1 Design 7

7.2 Types of formwork 7

7.3 Column forms 8

7.4 Access platforms 8

7.5 Erecting formwork frames 9

7.6 Intermediate platforms 10

7.7 Installing bearers 10

7.8 Installing joists 11

7.9 Laying formply on the deck 11

7.10 Cantilevers 13

MS-1146-025
Kuwait National Petroleum Company
(K.S.C) Method Statement P6012MAB-000-51-1-M308
Clean Fuels Project For REV. OA, 22-Mar-2015
KNPC Contract No. CFP/EPC/0054-MAB1 CAST-IN-SITU BAY Page 4 of 18
PSCJV Job No. JI-2025

7.11 Penetrations 13

7.12 Working areas for steel fixers and others 14

7.13 Changing floor levels 16

7.14 Fall protection form the formwork deck 16

8.0 Responsibility 16

9.0 Safety & Environmental Protection 17

10.0 Environmental Impact 18

11.0 Emergency Response 18

MS-1146-025
Kuwait National Petroleum Company
(K.S.C) Method Statement P6012MAB-000-51-1-M308
Clean Fuels Project For REV. OA, 22-Mar-2015
KNPC Contract No. CFP/EPC/0054-MAB1 CAST-IN-SITU BAY Page 5 of 18
PSCJV Job No. JI-2025

1.0 GENERAL

1.1 PURPOSE
The scope of this method statement is to cover the CAST-IN-SITU BAY
(Columns and Beams)

1.2 ABBREVIATIONS
COMPANY : Kuwait National Petroleum Company ( K.S.C) (KNPC)
MAB-1 : Mina Abdullah Refinery- Package 1
EPC CONTRACTOR : Petrofac International Ltd, Samsung Engg, CB&I ( PSCJ)
FEED : Front end engineering design
PMC : Foster Wheeler Energy Limited, UK

1.3 DETAILS OF THE PROJECT


 Name of the Project : Clean Fuels Project (CFP)
 Company Project Number :CFP/EPC/0054/MAB-1
 Commencement Date : 13th April, 2014

1.4 DEFINITION
 COMPANY TEAM is the integrated Project Management Team comprising of
KNPC and Foster Wheeler employees.
 Contractor Project Team is the “Petrofac Samsung Engineering CB & (PSCJV)
entrusted with execution of the PROJECT.

MS-1146-025
Kuwait National Petroleum Company
(K.S.C) Method Statement P6012MAB-000-51-1-M308
Clean Fuels Project For REV. OA, 22-Mar-2015
KNPC Contract No. CFP/EPC/0054-MAB1 CAST-IN-SITU BAY Page 6 of 18
PSCJV Job No. JI-2025

2.0 REFERENCES
2.1 KNPC/PSCJV Company CFP Project site SHE&S Plan HSE-TSSA-05-1118
2.2 KNPC/PSCJV SHE&S Plan HSE-TSSA-05-1118
2.3 KNPC/PSCJV Fuelling Operations HSE-TSSA-05-1118
2.4 KNPC/PSCJV Construction Risk Assessment HSE-TSSA-06-2029
2.5 KNPC/PSCJV Heat Stress Prevention SHE-TSOH-04-1313
2.6 KNPC/PSCJV Transportation Plan HSE-TSSA-05-1118
2.7 KNPC/PSCJV Safe Work Method Statement and JSA HSE-TSSA-05-1118
2.8 KNPC/PSCJV PTW Procedure HSE-TSSA-06-2029
2.9 KNPC/PSCJV Control of Power tools HSE-TSSA-05-1118
2.10 KNPC/PSCJV Manual Handling HSE-TSSA-05-1118

3.0 LOCATION
3.1 Location works is applicable to all project's areas.

4.0 EQUIPMENT
The major items of equipment envisaged for transportation are as follows:
4.1 Meter spirit level/Theodolites.
4.2 Transit mixer.
4.3 Concrete pump
4.4 Water Tanker.
4.5 Concrete Vibrators.
4.6 Hand tools.
4.7 Air Compressor.
4.8 JCB.
4.9 Bobcat.
4.10 Wheelbarrow.
4.11 Testing cube molds.

5.0 RESOURCES
5.1 Manpower allocated to this job will be as follows:
- Operators and drivers.
- Charge hands.

MS-1146-025
Kuwait National Petroleum Company
(K.S.C) Method Statement P6012MAB-000-51-1-M308
Clean Fuels Project For REV. OA, 22-Mar-2015
KNPC Contract No. CFP/EPC/0054-MAB1 CAST-IN-SITU BAY Page 7 of 18
PSCJV Job No. JI-2025

- Test Technicians.
- Laborers.
- Flagmen.
- Safety Officer.

6.0 KEY PERSONNEL


6.1 The Site Supervisor / Section Engineer in-charge of the concern area shall be
responsible for implementation of this method statement.
6.2 QA/QC Engineer to verify and report quality and compliance.

7.0 PROCEDURE
7.1 Design
7.1.1 The design of the final concrete structure can have a major effect on
the ease of formwork construction and the health and safety of people
during construction. Generally the more basic and simple the final
concrete structure, the safer it is to construct, erect and dismantle the
formwork.
7.1.2 Formwork designer should be consulted during the design of in-situ
concrete structures to enable the health and safety risks during
formwork construction and dismantling to be considered in the design.

7.1.3 The formwork designer must be competent in formwork design


including documenting temporary work platforms and special
equipment needed for safe formwork construction on-site.

7.1.4 Formwork should be:


7.1.4.1 Rigid, watertight, braced and tied together to maintain position
and shape during construction.
7.1.4.2 Able to be removed easily and safely without damaging the
formed concrete, or have components that remain as part of
the finished structure so the rest can be removed without
damaging the structure.

7.2 Types of formwork


The safety of workers erecting, using and dismantling the formwork should be
considered when choosing a formwork system for a particular job. In
particular consider stability, strength and the risk of falls, falling objects and
manual tasks. The best proprietary systems have integrated safety features to
help control the risk of falls and hazardous manual tasks.

MS-1146-025
Kuwait National Petroleum Company
(K.S.C) Method Statement P6012MAB-000-51-1-M308
Clean Fuels Project For REV. OA, 22-Mar-2015
KNPC Contract No. CFP/EPC/0054-MAB1 CAST-IN-SITU BAY Page 8 of 18
PSCJV Job No. JI-2025

Traditional formwork systems are typically constructed on-site from timber


or plywood and supporting elements like scaffolding.

When using a traditional system, a standard formwork frame with a known


tested loading capacity should be used wherever possible. Standard frames
can minimize the risk to workers erecting and dismantling the formwork and
handling and storing materials.

7.3 Column forms

7.3.1 Column forms should be designed to withstand wind loading before,


during and after the concrete pour. The bracing and forms should not
be removed from the cast element until it can safely withstand
potential impact loads and wind loads.

7.3.2 Lateral support can be provided to vertical elements in a variety of


ways including horizontal and angled braces and structural
connections to other parts of the building. A bracing element design
should be completed by a competent person.

7.3.3 The bracing element should also be able to resist both tensile and
compressive loads that may be applied by the wind.

7.4 Access platforms

7.4.1 Suitable access should be provided for wall and column forms and
may include purpose built access platforms.

7.4.2 Edge protection should be provided on the access platforms.


Preferred methods of entry to platforms include stair access systems
or if this is not practicable secured industrial ladders.

7.4.3 Platforms should also be designed to resist loading that may be


applied during a concrete pour to ensure the platform does not
collapse or overturn.

MS-1146-025
Kuwait National Petroleum Company
(K.S.C) Method Statement P6012MAB-000-51-1-M308
Clean Fuels Project For REV. OA, 22-Mar-2015
KNPC Contract No. CFP/EPC/0054-MAB1 CAST-IN-SITU BAY Page 9 of 18
PSCJV Job No. JI-2025

7.5 Erecting formwork frames

7.5.1 Formwork frames should be erected progressively to ensure the


installers’ safety and the stability
of the overall structure.

7.5.2 Braces should be attached to the frames as soon as practicable and


designated access ways should be indicated by using bunting or by
other means.

7.5.3 If side bracing or other edge protection is installed progressively on


formwork frames other control measures to prevent a fall occurring
may not be required.

7.5.4 Many conventional formwork frames consist of diagonal braces that


cross in the middle. While these braces are not considered to be
suitable edge protection for a completed formwork deck, they may
provide reasonable fall protection during frame erection. This is only
the case where braces are installed in a progressive manner as soon
as the frames are installed.

7.5.5 As the height of formwork frames increase there is a greater need to


provide lateral stability to the frames. Ensure framing, including
bracing, is carried out in accordance with on-site design
documentation and manufacturers’ instructions. People erecting
formwork must be trained to erect formwork using safe methods.

7.5.6 The risk of internal falls while erecting frames can be controlled by
fully decking each lift of the formwork decks and false decks. This
involves:

7.5.6.1 Positioning a full deck of scaffolding planks or other suitable


decking at each Bay.
7.5.6.2 Positioning decking on the next Bay while standing on a fully
decked platform.
7.5.6.3 Leaving each Bay fully decked in place until it is dismantled.

7.5.7 after dismantling of Formwork , decking should be removed while


standing on a fully decked platform immediately below.

MS-1146-025
Kuwait National Petroleum Company
(K.S.C) Method Statement P6012MAB-000-51-1-M308
Clean Fuels Project For REV. OA, 22-Mar-2015
KNPC Contract No. CFP/EPC/0054-MAB1 CAST-IN-SITU BAY Page 10 of 18
PSCJV Job No. JI-2025

7.6 Intermediate platforms

Where the potential fall distance is less than 2 meters, an intermediate work platform
can be provided that is at least 450 mm wide (see Figure 1).

Figure 1 Worker erecting formwork from an intermediate platform less than 2 meters
above a formwork deck where the deck to deck height is greater than 2 meters.

7.7 Installing bearers

7.7.1 Bearers are the primary horizontal support members for a formwork
deck that are placed on top of formwork frames. They are usually
timber but are sometimes metal. They should be placed in position by
people located on a secure platform no more than 2 meters below
them.

7.7.2 Bearers should be positioned so they will not fall off the top of the
frames. The usual method to do this is by placing the bearers in U-
heads on top of the frames and by minimizing cantilevers. U-heads
should be used where two bearers abut. Where only single bearers
are placed in the U-head, the bearer should be placed centrally in the
U-head unless a formwork designer, engineer or other competent

MS-1146-025
Kuwait National Petroleum Company
(K.S.C) Method Statement P6012MAB-000-51-1-M308
Clean Fuels Project For REV. OA, 22-Mar-2015
KNPC Contract No. CFP/EPC/0054-MAB1 CAST-IN-SITU BAY Page 11 of 18
PSCJV Job No. JI-2025

person states otherwise. This can be achieved by rotating the U-head


or by using timber wedges.

7.7.3 Where the top of the supporting member consists of a flat plate, the
bearer should be nailed or otherwise effectively secured to the plate.
Flat plates should only be used where specified by a formwork
designer, engineer or other competent person.

7.8 Installing joists

7.8.1 Where a false deck is provided at 2 meters or less below a worker,


joists may be spread on the bearers with the worker standing on top at
bearer level.

7.8.2 If the height of the formwork deck being constructed is more than 2
meters above a continuous deck or surface below it, joists should be
spread from a platform located within 2 meters of that surface,
underneath the deck being constructed by SGB scaffold materials
(see Figure 1). This work platform should be a false deck but an
intermediate platform may be used.

7.8.3 A person should be provided with a working platform at least 450 mm


wide (two planks) when the potential fall distance is less than 2
meters. It is not acceptable for a person to work from a single plank
or bearer.

7.8.4 One example of a work system that may be used to do this is as


follows:

7.9 Laying formply on the deck

7.9.1 A formwork deck should be laid in a progressive way so people will be


provided with a method to prevent them from falling below the deck.

7.9.2 This control measure is particularly important in situations where a


false deck has not been provided within 2 meters below the level of
the deck to be laid. In this situation form ply may only be spread on
the joists provided:

7.9.2.1 People start laying the form ply sheets from the perimeter scaffolding
or other edge protection provided on the perimeter of the formwork.

MS-1146-025
Kuwait National Petroleum Company
(K.S.C) Method Statement P6012MAB-000-51-1-M308
Clean Fuels Project For REV. OA, 22-Mar-2015
KNPC Contract No. CFP/EPC/0054-MAB1 CAST-IN-SITU BAY Page 12 of 18
PSCJV Job No. JI-2025

7.10 Cantilevers

7.10.1 Cantilevered bearers, joists and ply sheets can be hazardous when
left unsecured. The weight of material or a person standing on the
cantilever may make the timber see-saw and cause the person or
material to fall. When designing the formwork system, the use of
cantilevers should be kept to a minimum. In some situations using
cantilevered sections is unavoidable. In these cases, a formwork
designer should consider the potential for people and stored materials
to cause cantilevers to pivot.

7.10.2 Wherever the weight of a person will cause a cantilever to pivot, the
formwork design should include measures to secure the cantilevers so
this will not occur. This may include temporary propping, nailing,
bolting or another effective method. If nailing is used the formwork
design should specify the nailing detail and this should be followed.
This may include the use of purpose designed or proprietary brackets.
Materials should not be stacked or stored on a cantilever section
unless the section has been designed to carry the load. Temporary
working platforms cantilevered from shoring frames are a form of
cantilevered scaffold. Where a person or object could fall more than 4
meters from a scaffold, workers involved in erecting, altering or
dismantling them must hold a scaffolding license. The minimum
license class for this type of work is Intermediate Scaffolding.

7.11 Penetrations

7.11.1 Open penetrations like stairwells or penetrations to allow for services


create hazards for people on the deck, for example a fall through a
larger penetration, stepping into a smaller penetration or an object
falling through the opening onto people below. A penetration where
there is a risk a person or an object could fall through should be
guarded.

7.11.2 Protect open penetrations with edge protection like handrails or by


securely covering them so no one can fall through them. Penetrations
in concrete slabs may include cast-in-mesh as a back-up system. The
mesh should be of a small aperture, for example 50 x 50 mm mesh
size or smaller and made of material capable of withstanding the
potential imposed loads. Where mesh or other physical fall protection
material is to be provided for larger penetrations this should be
included in the slab design specifications to ensure it can withstand
potential loads including those applied by people, equipment
and material.
MS-1146-025
Kuwait National Petroleum Company
(K.S.C) Method Statement P6012MAB-000-51-1-M308
Clean Fuels Project For REV. OA, 22-Mar-2015
KNPC Contract No. CFP/EPC/0054-MAB1 CAST-IN-SITU BAY Page 13 of 18
PSCJV Job No. JI-2025

7.11.3 Where holes are cut in the mesh for services to pass through the hole
should be cut to the profile of the service so the mesh remains in the
penetration and the load carrying capacity of the mesh is not reduced
below design specifications.

7.11.4 Using plywood covers alone is not a satisfactory risk control because:

7.11.4.1 The cover may be indistinguishable from other pieces


of plywood.
7.11.4.2 It cannot be refitted without significant modification,
once the first service is installed.
7.11.4.3 It may be difficult to determine if the plywood is properly
secured.
7.11.4.4 Secured plywood covers can be unsecured to gain
entry and not re-secured.

7.11.5 Plywood covers should be structurally graded, painted in a bright color


and marked with wording, for example ’Danger penetration below’.
The cover should be firmly secured to the concrete and designed for
potential loads that may be applied, for example workers, materials or
plant that may travel over the cover.

7.11.6 Before stripping formwork, cover the penetration that will be exposed
as the formwork is stripped or protect the penetration before starting
the stripping operation.

7.11.7 Penetrations are also hazardous before the deck is laid. Joists placed
up to the edge of the penetration should be secured so the timbers
cannot spread if a person falls on them.

7.12 Working areas for steel fixers and others

7.12.1 Steel fixers, plumbers and electricians often follow closely behind the
formwork erection. The formwork zone should be large enough to
ensure these people are clearly separated from the form workers.

7.12.2 A ‘formwork only’ zone should be maintained behind the leading edge.
This zone should be clearly marked by signs and a mesh barrier.
Figure 3 shows the ‘other work’ zone, the ‘formwork’ zone and the
area retained as edge protection—four joists spaced 1800 mm beyond
the laid deck.

MS-1146-025
Kuwait National Petroleum Company
(K.S.C) Method Statement P6012MAB-000-51-1-M308
Clean Fuels Project For REV. OA, 22-Mar-2015
KNPC Contract No. CFP/EPC/0054-MAB1 CAST-IN-SITU BAY Page 14 of 18
PSCJV Job No. JI-2025

Figure 3 End view of deck showing working zones.

7.12.3 Temporary walkways laid across reinforcement mesh can be used to


control the risk of slips and trips when multiple trades are entering
large areas where reinforcement mesh has been laid behind
farmworkers.

7.12.4 A physical barrier should be provided and maintained to separate the


formwork work zone from other workers. This barrier should be rigid,
capable of maintaining its integrity in an upright position and capable
of supporting signage if required.

MS-1146-025
Kuwait National Petroleum Company
(K.S.C) Method Statement P6012MAB-000-51-1-M308
Clean Fuels Project For REV. OA, 22-Mar-2015
KNPC Contract No. CFP/EPC/0054-MAB1 CAST-IN-SITU BAY Page 15 of 18
PSCJV Job No. JI-2025

7.13 Changing floor levels

Formwork decks are rarely flat across the entire floor, generally due to deep
beams or ‘drop downs’ sometimes called ‘capitals’ around columns. Uneven
floors introduce fall hazards. These hazards are most effectively managed by
ensuring formwork supports and the deck are progressively constructed for
the lower parts of the deck before work starts on the higher-level areas of the
deck.

7.14 Fall protection from the formwork deck

7.14.1 During formwork construction the structure is constantly changing so


continual modification of fall protection measures is also necessary.

7.14.2 When there is only one leading edge where the other edges are
provided with scaffold edge protection or safety screens, providing fall
protection on the leading edge is relatively straightforward. However,
where there are multiple leading edges or the deck is not at one
consistent level, fall protection may be difficult to implement.

8.0 Responsibility

8.1 Quality Control Engineer shall be responsible to:

8.1.1 Ensure that all inspection and test report pertaining to


the work are submitted to the Engineer.
8.1.2 Ensure that all QCI’s and Lab Technicians are properly
informed as to the work programme and delegating
actions to QCIC.
8.1.3 Co-ordinate with other QC disciplines, as necessary.
8.1.4 Reject materials or workmanship that does not comply with
the Project Specifications.
8.1.5 Prevent the use of equipment that could lead to construction
workmanship not compliant with the project Specifications.
Stop any work that is not being done in accordance with the
specified requirements.

MS-1146-025
Kuwait National Petroleum Company
(K.S.C) Method Statement P6012MAB-000-51-1-M308
Clean Fuels Project For REV. OA, 22-Mar-2015
KNPC Contract No. CFP/EPC/0054-MAB1 CAST-IN-SITU BAY Page 16 of 18
PSCJV Job No. JI-2025

8.1.6 Report within 24 hours and provide records to and as required


by the Engineer upon discovery of non-compliance.

8.2 QA/QC Inspector shall be responsible to:

8.2.1 Ensure the proper implementation of contractor /


subcontractor quality system and maintain overall quality of
the work.
8.2.2 Conduct inspections and monitor the required tests.
8.2.3 Ensure that all personnel to be fully aware with all quality
requirements and application for all quality documents as
relevant to their discipline.
8.2.4 Ensure appropriate supervision control of all work activities so
that all quality related operations are effectively covered.

8.3 Organization, responsibility & Supervision

It is the responsibility of all personnel involved in this activity to


implement this method statement as stated hereinafter.

This shall be conducted in collaboration with the attached risk


assessment, KNPC SHE&S plan, and project safety rules and
regulations.

9.0 SAFETY & ENVIRONMENTAL PROTECTION

9.1 All equipment shall be certified and good working condition. Approved by
contractor and certificated as contract requirements.
9.2 All personnel involved in this task shall wear safety helmets, safety boots, safety
glasses and hearing protection.
9.3 Banks men, wearing distinctive vests, shall be assigned to help operators man
oeuvre their equipment especially when reversing and in tight situations.
9.4 The site shall be kept in a clean and tidy condition.
9.5 Equipment operators shall possess the required licenses and certificates.
9.6 All involved personnel shall have received the required safety induction training.
9.7 General dust (by wind and/or equipment operation), shall be controlled by
periodic water spraying. Workers to wear dust masks.
9.8 The required consolidated permit to work (PTW) shall be obtained prior to
commencement of work.

MS-1146-025
Kuwait National Petroleum Company
(K.S.C) Method Statement P6012MAB-000-51-1-M308
Clean Fuels Project For REV. OA, 22-Mar-2015
KNPC Contract No. CFP/EPC/0054-MAB1 CAST-IN-SITU BAY Page 17 of 18
PSCJV Job No. JI-2025

9.9 The project safety officer is responsible along with the project/section/ site
engineer for ensuring that all operations are carried out with due regard to the
safety of all project personnel and property.

10.0 ENVIRONMENTAL IMPACT

10.1 List environmental issues/impact that may arise while execution the
activities outlined in the method statement and describe mitigation
measures.

Impact Mitigation
Drivers shall switch off engines when the vehicle
1 Fuel consumption and generated gases or machine will be standing for longer period

2 Fuel and oil spillages Spill kits shall be held available close the work
area. Any contaminated soil will be removed from
site.
Dust generation impact (changes due to Water spraying shall be used for dust
3 wind and wind direction) suppression
Tires shall be cleaned prior trucks leaving the
4 Mud generation project area and going to
General housekeeping rules for all operatives
5 Waste management shall be observed.

11.0 Emergency response

Emergency Muster Point, First Aid Location and Contact Details:

EMERGENCY MUSTER POINT Muster Points will be sign posted on site

SITE LOCATION OF FIRST AID On site Ambulance will be the location of the
FACILITIES First Aid until the First Aid Point is established.

NAME OF FIRST AIDER ON


SITE

COMPANY CAMP DUTY OFFICER


CLINIC

MS-1146-025
Kuwait National Petroleum Company
(K.S.C) Method Statement P6012MAB-000-51-1-M308
Clean Fuels Project For REV. OA, 22-Mar-2015
KNPC Contract No. CFP/EPC/0054-MAB1 CAST-IN-SITU BAY Page 18 of 18
PSCJV Job No. JI-2025

LOCATION AND DISTANCE


OF NEAREST MEDICAL UNIT:

Emergency Contact Number


888

SUBCONTRACTOR Site Supervisor shall notify the CONTRACTOR of any injury to


personnel. All injuries, irrespective of their severity shall receive adequate medical
attention and must be recorded in the site logbook according to the
SUBCONTRACTOR’s HSSE recordkeeping procedures.
All contact numbers will be tested and verified by CCC HSSE Manager for response
and validity prior to work commencing.

MS-1146-025