Rohan Builders (India) Pvt. Ltd.

FABRICATION
METHOD
STATEMENT

ROHAN BUILDERS (INDIA) PVT. LTD.

C/O TETRA PAK (INDIA) PVT. LTD.
CHAKAN MIDC PHASE II
PUNE

Fabrication Method Statement

Page 1

CONTENTS

Rohan Builders (India) Pvt. Ltd.

1.
2.
3.
4.
5.

PURPOSE
SCOPE
RAW MATERIAL INSPECTION
MATERIAL LOADING, UNLOADING AND STACKING
FABRICATION WORK
a. Raw Material Shifting To Work Place
b. Straightening Of Raw Material
c. Marking On Raw Material As Per Cutting Plan
d. Inspection Of Marking Before Cutting
e. Preparation For Cutting And Drilling
f. Cutting And Drilling As Per Marking
g. Shifting Of Cut Items To Sub Assembly Area
h. House Keeping Of Cutting Area
i. Fitment Of Sub Assembly As Per Drawing
j. Inspection Of Sub Assembly Fitment
k. Welding Of Sub Assembly
l. Inspection Of Welded Sub Assembly
m. Shifting Of Sub Assembled Part To Final Assembly
n. Fitment Of Final Assembly
o. Inspection Of Final Assembly Fitment
p. Welding Of Final Assembly
q. Inspection Of Welded Final Assembly
r. Shifting Of Final Assembly To Shot Blasting Area
6. SHOT BLASTING WORK
a. Preparation For Shot Blasting
b. Shot Blasting Of The Job
c. Inspection Of Shot Blasted Job
d. Shifting Of Shot Blasted Job To Painting Area
5. PAINTING WORK
a. Preparation For Painting
b. Primer Painting Of The Job
c. Inspection Of Primer Painting
d. Painting Of First Coat
e. Inspection Of First Coat
f.
Painting Of Final Coat
g. Inspection Of Final Coat
h. Shifting Of Job To Erection Area

1. PURPOSE
The purpose of this generic method statement is to define the
procedure for Fabrication & Erection work for Industrial building.

Fabrication Method Statement

Page 2

Rohan Builders (India) Pvt. Ltd.

2. SCOPE
Scope of this method statement covers the following activities.

Material handling
Fabrication
Welding
Shot blasting
Painting
Erection
Alignment

3. RAW MATERIAL INSPECTION

Pre-inspection of raw material, visually for any flaws, defect,
twist, bend, lamination, etc.
Pre-inspection of raw material, physically for sectional
dimensions, length and width as per PO raised.
Pre-inspection for availability of valid MTC as per IS code.

4. MATERIAL LOADING, UNLOADING AND STACKING

LOADING
Material loading should be done by using approved lifting
tools and tackles as per IS code.
Depending upon the materials weight, size & length, the
lifting tools are to be selected.
Proper guide rope should be provided at the end of material.
The trailer onto which the material is to be loaded should be
at proper position.
Proper resting support to be provided on trailer before
placing of material.
Fabrication Method Statement

Page 3

Rohan Builders (India) Pvt. Ltd.

UNLOADING
Depending upon the materials weight, size & length, the
lifting tools are to be selected.
Proper guide rope should be provided at the end of material.
Area where material is to be unloaded should be leveled and
wooden logs or concrete slippers to be provided at proper
spacing.
STACKING
Stacking area should be leveled and wooden logs or concrete
slippers to be provided at proper spacing.
Different types of material should be stacked separately.
Material identification/heat no. should be highlighted.
Proper name plates should be provided for different material.

5. FABRICATION WORK
a. Raw Material Shifting To Work Place
The material to be use for fabrication should be shifted by
combination of hydra and trailer for distances which are far,
where as for very short distances only hydra to be used.

b. Straightening Of Raw Material

Fabrication Method Statement

Page 4

Rohan Builders (India) Pvt. Ltd.

The raw material to be used should be inspected for any bend.

Bend lines to be marked on the bend area. This bend lines will
be the reference for removing of bend. For light material/minor
bend hammering can be conducted, where as for heavy
material, straightening jack is to be used.

c. Marking On Raw Material As Per Cutting Plan

Material to be marked should be placed on horizontal straight
surface. Material should be free from dust, oil, etc. Marking
should be conducted only as per cutting plan. It should be
done by using thin cotton string & chalk powder. Geometrical
methods should be applied for right angle marking.

d. Inspection Of Marking Before Cutting

The marking done should be cross checked with the cutting
plan by the engineer. It should be checked with all aspect,
considering tolerance as per IS code. The measuring tools,
such as metallic tape, tri square, vernier, etc., used should be
calibrated one.

e. Preparation For Cutting And Drilling

All the equipments required should be arranged at the work
place. It should be ensured that each and every equipment is
of approved quality.
For cutting, equipment like pug cutting machine, cutting torch,
hose pipe, flash back arrester, gas regulator, acetylene
cylinder, oxygen cylinder, spark lighter, pug machine rail and
supportive tools should be used.
Whereas, for drilling, magnetic drill machine, drill bit, coolant
and supportive tools should be used.
Fabrication Method Statement

Page 5

Rohan Builders (India) Pvt. Ltd.

f. Cutting And Drilling As Per Marking

Before cutting by pug machine it should be ensured that the
drilling activity is conducted first. This helps the drilling activity
to be more accurate and safe in terms of material hardening
by cutting. Depending upon the final hole size the pilot drill
size should be decided, it helps for accuracy.
Once the drilling activity is completed, the material is ready to
be cut. For this the pug rails should be placed first with respect
to cutting line and the setup should be made such that it
doesnt obstruct the cutting. Proper speed and distance should
be maintain for good quality cut.
g. Shifting Of Cut Items To Sub Assembly Area
Once the cut items are cooled it should be shifted to sub
assembly area. The shifting will be within the yard so no need
of trailer for the same. For shifting of small parts manual lifting
by hand can be allowed. Whereas for heavy parts, proper
slings should be used and guide rope should be provided
wherever applicable. The shifting done should place on leveled
surface with proper packing.
h. House Keeping Of Cutting Area
After shifting of cut items, the cutting area should be cleaned
properly and the scrap material or extra material should be
placed on its position. No man movement should be allowed at
housekeeping area unless the area is cleared.
i. Fitment Of Sub Assembly As Per Drawing
Depending upon type of welding the equipment required
should be listed out, such as, for MMAW, welding rectifier with
approved electrode and IS marked attachments should only be
used. Whereas for Submerge Arc Welding, SAW machine with
Fabrication Method Statement

Page 6

Rohan Builders (India) Pvt. Ltd.

approved electrode and IS marked attachments should only be

used.
Fitment of sub assembly differs from one type of member to
the other. It includes fitment of Rafter, Column and Beam,
which are as below:
RAFTER
After receiving the cut items to the sub assembly area, the
plates for built-up rafter should be placed on platform in such a
way that it should be easy to tack weld from both sides. The
tack welding should be conducted by MMAW process and the
welding should be done by a qualified welder only. The
purpose of tack welding is to bring the work piece to the
required design as per drawing and then inspection of the
same is to be done.
COLUMN
For column fitment, the rolled section, connection cleat and its
base connection material should be placed on platform and
assembled as per approved drawing. The tack welding for the
same is to be done by MMAW process and by a qualified
welder only. The work piece should be placed on platform in
such a way that it should be easy to rotate, for tack welding.
Inspection of the same should be conducted after tack weld.
BEAM
For beam fitment, the rolled section and connection cleat
should be assembled as per approved drawing. The tack
welding for the same is to be done by MMAW process and by a
qualified welder only.
j. Inspection Of Sub Assembly Fitment
After sub assembly fitment the job should be checked by the
engineer. The engineer should check the following things;
dimensions of the job, accuracy as per tolerance,
Fabrication Method Statement

Page 7

Rohan Builders (India) Pvt. Ltd.

perpendicularity of each part, etc, as per approved drawings

and clients technical specification.
k. Welding Of Sub Assembly
Welding of sub assembly for rafter should be done by SAW and
rest other sub assembly should be welded by MMAW process.
For rafters, the part to be welded should be placed on fixture
which should be in 45. Adjacently the welding set should be
placed on the tracks and the welding torch to be adjusted at
the plate joint. The welding to be conducted as per specified
radius and as per given drawing. The flux used should be
baked in oven as per specified. Proper welding techniques
should be applied to avoid welding distortion. When the full
length of weld is achieved on one side of the job, it should be
overturned by crawler crane to weld from other side.
For columns and beams, MMAW welding should be done. For
electrodes like E7018, which are low hydrogen electrodes,
baking should be done before it is use as per specification.
Proper welding techniques should be applied to avoid welding
distortion.
l. Inspection Of Welded Sub Assembly
There should be 100% visual inspection of welded parts, for
any spatters, slag inclusion, porosity, welding radius, etc. as
per specification. Whereas 20% of DPT inspection should be
conducted for fillet as well as for butt joints. The DPT should be
conducted by the authorized person and check list to be filled
for the same.
m. Shifting Of Sub Assembled Part To Final Assembly
Once the inspection is passed, the job should be shifted to
final assembly. The shifting will be within the yard so no need
of trailer for the same. Since at this stage the weight of the
Fabrication Method Statement

Page 8

Rohan Builders (India) Pvt. Ltd.

job is increases due to assembly welding, precaution should be

taken for selection of lifting equipment. Combination of two
cranes can be taken for heavy assembly wherever needed.
The approved lifting tools and tackles should be used for lifting
and guide ropes shall be provided for lengthy jobs.
n. Fitment Of Final Assembly
At this stage only huge jobs like Rafters and NLGs will require
final assembly. These fitments are such as resting stools,
cleats, end plates, etc. The fitment should be done as per
approved drawings only. Tack welding of parts should be done
by MMAW process and by using proper tools and tackles.
o. Inspection Of Final Assembly Fitment
After final assembly fitment the job should be checked by the
engineer. The engineer should check the following things;
dimensions of the job, accuracy as per tolerance,
perpendicularity of each part, etc, as per approved drawings
and clients technical specification.
p. Welding Of Final Assembly
For final assembly parts, such as cleats, end plates, etc. MMAW
process shall be conducted. For electrodes like E7018, which
are low hydrogen electrodes, baking should be done before it
is use as per specification. Proper welding techniques should
be applied to avoid welding distortion.
q. Inspection Of Welded Final Assembly
There should be 100% visual inspection of welded parts, for
any spatters, slag inclusion, porosity, welding radius, etc. as
per specification. Whereas 20% of DPT inspection should be
conducted for fillet as well as for butt joints. The DPT should be
conducted by the authorized person and check list to be filled
for the same.
Fabrication Method Statement

Page 9

Rohan Builders (India) Pvt. Ltd.

r. Shifting Of Final Assembly To Shot Blasting Area

Since the shifting is from one yard to other yard, i.e., from
fabrication yard to ware house west, it should be shifted with
combination of hydra and trailer. The ready material shall be
calculated for weight and depending upon it the lifting tools
and tackles should be decided. Proper packing material shall
be provided between material and trailer for placing of
material. The length of trailer should be sufficient to cover the
material length. The shifting route should be pre planned and
shall be clear from any obstructions.
7. SHOT BLASTING WORK
a. Preparation For Shot Blasting

b. Shot Blasting Of The Job

c. Inspection Of Shot Blasted Job

d. Shifting Of Shot Blasted Job To Painting Area

6. PAINTING WORK
a. Preparation For Painting

Fabrication Method Statement

Page 10

Rohan Builders (India) Pvt. Ltd.

b. Primer Painting Of The Job

c. Inspection Of Primer Painting

d. Painting Of First Coat

e. Inspection Of First Coat

f.

Painting Of Final Coat

g. Inspection Of Final Coat

h.

Shifting Of Job To Erection Area

Fabrication Method Statement

Page 11