MAX INFRASTRUCTURE LTD [MIFL UNIT-2].
STATEMENT METHODE OF STEEL & BRIDGE
STRUCTURE
Doc. No.: SM/01
Revision: A
Date: 04/06/2023
The Primary goal of MAX Infrastructure Limited (MIFL Unit-2) is the satisfaction of
customers, we design, detail and fabricate our structures, machines, tanks etc using sound principle of
engineering and we fabricate every component with utmost attention to quality and detail.
STEEL STRUCTURE & BRIDGE STRUCTURE
METHOD STATEMENT
INDEX
1.0 SCOPE OF WORK
2.0 ACCESS/EGRESS
3.0 RESPONSIBILITY
i) PROJECT DIRECTOR
ii) CHIEF PROJECT MANAGER
iii) SITE ENGINEER
iv) SURVEYOR
v) SAFETY INCHARGE
vi) P&M ADMIN INCHARGE
vii) QUALITY INCHARGE
viii)
SHOP QC
ix) SHOP SAFETY
x) STORE
4.0 STORAGE & STACKING OF MATERIAL
5.0 SAFETY MEASURES AND PRECAUTIONS
6.0 PLANT & EQUIPMENT
7.0 TRAINING:
8.0 LOCATION, WORKMANSHIP AND SITE CONDITION WORKING AREA
9.0 MATERIALS
10. LIFTING AND SHIFTING OF STRUCTURAL STEEL
11. STORAGE & PROTECTION
12. MATERIAL INSPECTION, APPROVAL & TRACEABILITY
13. WELDER QUALIFICATION APPROVAL & TRACEABILITY
14. PREFABRICATION
15. INSTALLATION OF STEEL STRUCTURES
16. INSPECTION
SCOPE OF WORK:
Propose of this Method Statement is to describe the sequence of activities which will be followed to
execute the Bridge Structure fabrication works, testing, including unloading of the raw materials and
loading of fabricated materials to dispatch.
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MAX INFRASTRUCTURE LTD [MIFL UNIT-2].
STATEMENT METHODE OF STEEL & BRIDGE
STRUCTURE
Doc. No.: SM/01
Revision: A
Date: 04/06/2023
ACCESS / EGRESS:
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Proper access and egress will be ensured before and till completion of work.
Temporary signage will be provided at access and egress. Approachesand exits shall be clearly
defined by barricades and warning/caution signs.
Proper illumination and ventilation as per EH&S Plan/ Manufacture recommendation will be
ensured at site during work and shall be monitored periodically.
Necessary safety precautions will be taken for works at heights.
RESPONSIBILITY
PROJECT DIRECTOR
Organize and manage all resources, field activities required to the execution team with due regard to safety
and meeting product quality requirements. Planning of resources in line with schedule, specifications,
drawing details and liaison with Client, statutory and regulatory authorities.
CHIEF PROJECT MANAGER
To ensure that all the equipment, tools and tackles required to execute the works according to approved
construction Schedule are available in good condition and provide any additional equipment as required.
To ensure all the equipment/vehicles are handled by licensed / skilled operators. To provide all necessary
support to his construction team and ensure that the works are carried out as per the approved Method
Statements/procedures. Co-ordinate with site engineer, Surveyors, Safety Engineer, Quality Engineer, and
frontline supervisors for safe & proper execution of the works. To ensure that, checked levels shall be
entered in level books as per the approved formats & requirements on daily basis. To ensure that levels are
jointly being signed by the contractor and Client representative To continuously check the progress of works
as per schedule / programs. To ensure Client approval on all checklists / permission as and when required.
SITE ENGINEER
Understanding the drawings prior to start of work and all details are provided to execute the work. If not,
then take clarification from Client. Compliance to EHS and QA/QC requirements prior to commencement
of work. Engaging workmen in work according to plan.
Cross checking the activities intermittently during day’s work and ensuring the activity is done within
tolerance limits. Mobilizing the materials required for work prior to start of work. Preparing safe to work
card for all activities and giving Performance Enhancement Program (PEP) talk based on the safe to start
work card as part of the work instruction to workmen working under him highlighting the risk involved in
the task. To ensure safety of workmen working in his area. To ensure proper working platform with access
to keep materials. To ensure all working and checking tools are available at site with working team before
start of work. To ensure proper housekeeping at site at the end of day’s work. Understanding EHS
requirements of project from EHS plan, EHS management systems, EHS Manual & following the same in
execution of work. Marking legibly grid reference/ Date of construction. Ensuring implementation of
proper work methodology for all activities. Preparation of all checklists and certification of works from
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MAX INFRASTRUCTURE LTD [MIFL UNIT-2].
STATEMENT METHODE OF STEEL & BRIDGE
STRUCTURE
Doc. No.: SM/01
Revision: A
Date: 04/06/2023
Client. Ensure that all construction equipment and vehicles are inspected and cleared by P&M and EHS
department.
SURVEYOR
To establish bench marks from agreed reference points, provide required setting out and line and level
markings and follow up regular checks. Co-ordinate with site engineers and ensure that the survey works
are carried out according to the latest drawing. Maintain survey details and reports.
SAFETY INCHARGE
Shall inspect in maintaining safe working environment &conditions and compliance to Project EHS Plan.
Shall facilitate in EHS Risk analysis and ensure required preventative measures. Identify potentially unsafe
acts, areas and practice and educate people Monitor EHS practices, persuade to minimize noncompliance
Report incidents beyond control and unsafe occurrences. Issue stop work notice for unsafe work.
Investigate unsafe occurrences and initiate preventive steps. Discuss near miss accidents with staff and
workmen Conduct safety training programs and celebrations Review Health & Environment related aspects
as per the norms.
P&M/ ADMIN INCHARGE
Ensure availability of all statutory documents related to safe use of all construction equipment and vehicles
such as dumpers, excavators, and passenger vehicles (if any).To facilitate site team for all enabling work to
carry out works safely without any interruption.
QUALITY INCHARGE
Communicating with all site staff about the Quality requirements as per QMS Shall ensure all inspections
and tests are conducted as per approved Inspection and Test Plan. Shall ensure only approved materials
incorporated in works. Closure of Non-conformance, if any.
SHOPE QC
Ensure that Raw Material is as per approved make and traceability maintained. Ensure required training
and induction provided to all workers/supervisors. Ensure fabrication procedure is as per approved
Fabrication Method Statement. Ensure all testing performed, witnessed and verified by Inspection agency.
SHOP SAFETY
Aware about all works procedures and risk involve in it and all necessary precautions has been taken before
commencement of fabrication works. Ensure all induction and training provided to workman related to
safety.
STORE
store personal will collect invoices and MTCs of all material received at Fabricator’s end. Maintain the
record of incoming materials from Fabricators and dispatch record.
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MAX INFRASTRUCTURE LTD [MIFL UNIT-2].
STATEMENT METHODE OF STEEL & BRIDGE
STRUCTURE
Doc. No.: SM/01
Revision: A
Date: 04/06/2023
STORAGE & STACKING OF MATERIAL:
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Stacking of all steel plates shall be proper, size and section wise.
Material shall not be stacked directly on earth. It should be at-least300mm above from the ground
and to be kept on wooden planks.
It shall be stored in open to atmospheres, either it’s in shaded area or shall be covered properly
with Tarpaulin sheets.
Rolled section shall be stacked in such a way that edges of section not damaged.
Height of stack shall not be exceeded from 2 mtrs.
SAFETY MEASURES AND PRECAUTIONS:
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All the manpower involved in the job shall wear appropriate personal Protection equipment’s like
Helmet, Safety shoe, gloves, nose masks and safety belt wherever required.
Proper approach to the work spot, and proper illumination shall be maintained.
Ensure that height work permit is obtained to start that job and life line provision available if
required.
All precautions shall be taken care for loading, unloading and shifting of materials.
Housekeeping shall be done and all paint marks and splashes on surrounding surfaces will be
cleaned after completion of work.
Ensure that relevant risk assessment is available with the engineerduring activity.
PLANT & EQUIPMENT:
A.Plant & Equipment Schedule
The equipment engaged for works shall be checked and approved by shop P&M Department. All equipment
engaged in works shall be calibrated. List of equipment and calibration certificate of the same shall be
provided to Employer’s engineers for records.
Machinery/Tools/Equipment engaged to carryout works are as follow:
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Automatic Shot Blasting Machine
SAW Machine
Lifting Chains
Lifting Clamps
Auto Gas Cutter
Hand Gas Cutter
Welding Machine.
Grinding Machine.
All Hand Tools like Hammer, Chisel, Gas heating torch, Spirit level, measuring tape etc.
Electrode Baking oven
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MAX INFRASTRUCTURE LTD [MIFL UNIT-2].
STATEMENT METHODE OF STEEL & BRIDGE
STRUCTURE
Doc. No.: SM/01
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Revision: A
Date: 04/06/2023
Shear Machine
Profile Machine
Punch Machine
Crane
B.Personal Protective Equipment
All workmen should wear proper Personal Protective Equipment (PPEs) like safety helmets, safety belt,
hand gloves, eye protection glass, nose mask, gumboots/safety shoes, and reflective jackets etc.as
applicable.
TRAINING:
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Proper Tool box talk shall be given by Engineers to Supervisors and labors on the job specific
requirements.
Ensure that all workers engaged are properly gone through induction process.
Training for all potential safety hazards like loading/unloading, lifting/shifting/electrical safety,
impact of corrosion and water legginged. shall be provided to all workman.
General awareness training for Workers shall be organized by Quality Department.
LOCATION, WORKMANSHIP AND SITE CONDITION WORKING AREA:
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Location of all fabrication yard including working area shall be provided to Employer’s
Engineer separately.
Site condition of working area shall be as per industrial norms, nature and quantum of works.
All steel work before and after fabrication shall be straight and freeform twist.
All component parts shall be assembled in such a manner that they are neither twisted nor
otherwise damaged, and forcible connection to fit the members together shall not be used.
Load-bearing connections containing more than one type of fasteningshall not be used unless
specified or approved by the Inspector.
MATERIALS:
All the materials used shall be as per Approved make list.
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Steel Plates.
Rolled Section
Welding Electrode/ Consumables
LIFTING AND SHIFTING OF STRUCTURAL STEEL:
Fabricator assistant Stores to unload the RM being supplied by the main contractor at designated location
at fabricator’s storage yard grade-wise, thickness-wise etc. Everyone involved in the unloading of RM must
take all necessary safety precautions to reduce the risk of incidents. In particular, unloading should never
be carried out unless all the risks have been assessed, even if this results in a delay. Such delays can be
avoided through proper planning. Structural Steel shall be new and shall be well and cleanly rolled to the
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MAX INFRASTRUCTURE LTD [MIFL UNIT-2].
STATEMENT METHODE OF STEEL & BRIDGE
STRUCTURE
Doc. No.: SM/01
Revision: A
Date: 04/06/2023
dimensions, sections and weights specified. It shall be sound and free from cracks, surface flaws,
laminations and other defects and shall be finished in a workmanlike manner.
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Structural Steel will be unloaded as per size (Thickness) and properly stacked by using wooden
sleepers properly placed so that at the time of cutting sleepers will not come under the cutting zone
to avoid additional handling of material during cutting.
Crane/Hydra will be placed between the cutting bed and the assembly platform so that it can be
operated from the same area for both the platform to reduce the material handling time.
Lifting Equipment-:
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All lifting equipment like lifting chains, D-shackles, lifting clamps will be asper capacity with
proper safety norms and proper test certificate from the manufacturer/load test approved by
authorized MAX Infrastructure Limited as per Factories Act.
No lifting belt or wire rope will be used for loading /unloading purpose for unloading handling of
material trained man power (Rigger) will be engaged.
The Lifting Operations and Lifting equipment required ensuring that all operations, such as
unloading/loading/ handling from one area to other area of steel, are properly planned by
a competent person, appropriately supervised and carried out in a safe manner.
Lifting equipment will be used to be suitable for the use to which it is being put, properly
maintained, marked with its safe working load, and periodically thoroughly examined and
inspected before start of unloading /loading/handling of plates.
STORAGE & PROTECTION:
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All materials shall be stacked in such a way that edges and coating of materials not damaged.
If the material has to be stacked for long time, the same has to be covered by tarpaulin sheet.
Electrode shall be stored in Mother over as per requirement and manufacturer’s recommendations.
At field/shop, electrodes will be kept in portable ovens.
MATERIAL INSPECTION, APPROVAL & TRACEABILITY: •
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Raw Material (Structural Steel), welding electrodes/ consumables has to be inspected by EPCC.
Invoice and respective MTCs has to be collected and verified by EPCC.
After inspection of EPCC the same shall be offered to Employer’s/Engineer’s
Representative/Inspector for approval.
Physical condition of material and dimensions will be verified randomly by EPCC, Employer’s
representative/Inspector.
Traceability of Raw Material with invoice and MTC has to be verified.
Heat/Batch no. written/embossed/stenciled/stickered over Raw Materialshall be matched with
MTC.
Reference of MTC shall be mentioned in respective invoice or visa-versa.
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MAX INFRASTRUCTURE LTD [MIFL UNIT-2].
STATEMENT METHODE OF STEEL & BRIDGE
STRUCTURE
Doc. No.: SM/01
Revision: A
Date: 04/06/2023
WELDER QUALIFICATION APPROVAL & TRACEABILITY: •
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Welders will be qualified as per approved WPS/PQR.
WPS and PQR shall be submitted separately to Employer’s Engineer for approval.
After approval of WPS, test coupon will be prepared (duly witnessed by EPCC & Employer’s
Engineer/Inspector) as per approved WPS and test coupon will be send to approved third party
laboratory for testing.
If the test coupon passes in all specified parameters, PQR will be freeze.
On the basis of approved PQR, welder qualification test shall be performed.
Qualified welders shall be provided unique welder ID
List of qualified welders along with respective welder ID number shall be provided to
Employer’s Engineer to review and records.
Welder traceability can be verified fit-up and weld visual report and asper approved WPS/PQR.
PREFABRICATION
General requirements
Although not preferred, sometimes the prefabrication of steel structures & Bridge structures is performed
at Site. In this case, these works shall be closely monitored and audited by the Site Quality Control
department in accordance with the related Inspection and Test Plan. The works should also be undertaken
in accordance with the approved Health, Safety and Environment Plan. The prefabrication works at site are
mainly for steel supports. The same rules mentioned above will apply to these works. Works will be
implemented and controlled in accordance with the related Inspection and Test Plan. If it is found necessary
by the auditors, personnel training shall be arranged prior to prefabrication works. Therefore, what is meant
by prefabrication works is generally prefabrication of supports.
Preparation
To avoid any damage that may be occurred during handling of painted materials, lifting shall be done by
slings. All fabrication drawings, issued as “APD – As Per Design” shall be carefully reviewed and Cutting
Plans / Lists shall be prepared for each type and size of material, to minimize wastage of materials and to
minimize the amount of welding.
Marking and cutting
Plates, generally shall be prepared by flame & auto cutting followed by grinding. Profiles and or tubulars
shall be cut by various types of profile cutters, Auto Cutters. Surfaces to be welded shall be visually
examined to ensure that they are free from laminations, cracks, slag inclusions and cutting notches. Any
such defects shall be modified by grinding or brushing. The weld area shall be dry, clean and free from
loose scale or paint. Auto Cutting edges which are not subsequently welded shall be ground smooth to
remove nicks and burrs. The use of flame gouging or “washing” is not permitted.
Alignment, fit up and welding Prior to commencement of welding of steel structures & Bridge structures,
Welding Procedure Specifications (WPS) for each type of weld, shall be prepared and submitted for
approval. All welders shall be qualified in accordance with Welding Specification and qualified welder list
shall be submitted to the Client prior to commencement of the welding activity and updated periodically.
Parts to be welded will be cut as shown in drawings and after fit up by tack weld, the weld will be done as
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MAX INFRASTRUCTURE LTD [MIFL UNIT-2].
STATEMENT METHODE OF STEEL & BRIDGE
STRUCTURE
Doc. No.: SM/01
Revision: A
Date: 04/06/2023
per WPS (Welding Procedure Specification). Tack welds shall be at least 50 mm (AWS D1.5 CLAUSE-5,).
Parts to be joined by fillet welds shall be brought into as close contact as practicable. Welds, including tack
welds, will be performed by the qualified welders. Welds shall generally be in fabrication shops. Outdoor
welding, if necessary, shall be protected from adverse weather effects by means of protective measures.
Temporary attachments or similar devices required for prefabrication shall be removed by flame cutting or
grinding. Hammering is not permitted. When temporary attachments are removed, the surface of the base
metal shall be ground smooth and visually examined. Any defects discovered in the base metal such as
cracks or undercuts shall be removed and if necessary rewelded, and the area shall be examined. Concrete
reinforcing bars shall not be used as temporary attachment material. If the drawing shows holes for bolting,
holes shall be 2 mm larger in diameter than the specified bolts, unless otherwise noted on the fabrication
drawings. Bolt holes shall be drilled to size, or drilled and reamed if necessary. Enlarging by thermal means
is not permitted. Holes shall be clean-cut without burrs and torn or ragged edges. All holes shall be finished
prior to application of any protective coating.
Surface preparation and painting
After all fabrication of the components are completed, the components will be released for painting.
Surface preparation and painting shall be done in accordance with the approved Surface Preparation and
Painting Procedure.
INSTALLATION OF STEEL STRUCTURES
Adequate scaffolding material, temporary supports or tension rope cables shall be provided and used during
installation of steel structures and Bridge Structure. By using temporary braces, partially completed
structural assemblies to be ensured safe and stable conditions. The structure shall be plumbed, leveled and
braced before final bolted or welded connections are made. Column base plates shall be set and shimmed
to correct positions, elevations, and locations as shown on the erection drawings. After grouting, anchor
bolts shall be tightened. Temporary attachments shall be removed after the installation is completed.
Welded and bolted connections
Field welding shall only be used if so, required on the related drawings. Marking, cutting, alignment, fit-up
and welding which may be required during the installation of the structures shall be performed in
accordance with related specifications/procedures. High strength bolt assemblies shall be installed in
accordance with specification and standards. Steel structure elements are generally connected by high
strength bolts and handrail and grating connections are done by standard bolts and nuts. The type of
bolts/nuts will be in accordance with drawings. Bolt lengths shall be sufficient to extend approximately 5
mm through the nut. Fitted bolts shall clear the hole before the thread starts. Bolts and nuts shall rest
squarely against the metal. Bolts shall be tightened in accordance with tensioning requirements (snug tight
or fully tensioned) given in the related drawings and specifications. Bolt heads shall be carefully tapped
with a hammer while the nut is being tightened. All nuts for high strength bolts shall be wax-dipped to
reduce torque during installation. When assembled, all joint surfaces, including those adjacent to the bolt
heads, nuts or washers shall be free from burrs, dirt and other foreign materials that would prevent solid
seating of parts. All bolt assemblies shall be fully tightened. Bolts and nuts shall not be welded under any
circumstances. Direct tension indicator washers, if used, shall be installed according to the manufacturer’s
instructions. When impact wrenches are used, wrenches of adequate capacity and sufficient air supply shall
be used to perform the required tightening of each bolt. Mechanically galvanized bolts shall not be mixed
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MAX INFRASTRUCTURE LTD [MIFL UNIT-2].
STATEMENT METHODE OF STEEL & BRIDGE
STRUCTURE
Doc. No.: SM/01
Revision: A
Date: 04/06/2023
with hot dip galvanized nuts and bolts. Used bolts shall not be used again and also, they shall not be used
as fit-up bolts. Ends of the torqued bolts shall be marked by permanent marking paint to indicate that the
bolts have been properly tensioned and are ready for inspection.
Correction of errors
Bolts shall not be improperly used. Drift pin can be used to help for bolting process but it shall not be driven
with such force as to damage the adjacent metal areas. Holes may be carefully enlarged in accordance with
the standards, when the connection cannot be done due to minor misfit. Enlargement of holes shall be by
reaming or drilling only. Flame cutting, burning, gouging, chipping or drift punching shall not be permitted.
Holes in connections that misfit by more than 1.5 mm can only be corrected if allowed as per specifications
and as directed by the Client’s representative. All damages done during the erection works to hot dip
galvanized coatings and to shop applied paintings, shall be repaired in accordance with the approved
Surface Preparation and Painting Procedure,
INSPECTIONS
Structural Steel or Bridge Structure Installation shall be inspected in accordance with the approved
Inspection and Test Plans (ITP). Related tables of the ITP cover all inspection activities for Structural Steel
Installation, in chronological order. Main segments of ITP will be; definition of the work, referenced
documents for the work, examination/inspection method, evaluation of the result, involving parties
(contractor, client, etc.) and report forms for recording. Personnel executing the inspections should have
sufficient experience in the similar work.
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