PROJECT / UNIT

JOB
Khurais Area Facilities Expansion & Satellite GOSP
032184
Project
PLANT LOCATION
Doc. No. 000-ZA-E-T09405
Khurais– SAUDI ARABIA

General Method Statement for Precast Concrete Rev. C 04-APRIL-18

General Method Statement for

Precast Concrete

CONTRACTOR review result 1: Approved

by 2: Approved with comments
3: Rejected

Department Date Name Signature

Technical Discipline 1 2 3
Field Engineering Dept. 1 2 3
HSE Dept. 1 2 3
QA/QC Dept. 1 2 3

1: Approved
2: Approved with comments
COMPANY review result by 3: Rejected
Date Name Signature
1 2 3

REV DATE Prepared Checked Checked Approved Approved

Jaycy Yutuc Readolf Fedelin Rubenel Javier Ahmad Shibi Abdullah Hani
C 04-Apr-18
QCDC HSE Mngr. QC Mngr Const. Mngr. Proj. Dir.
Jaycy Yutuc Readolf Fedelin Rubenel Javier Ahmad Shibi Abdullah Hani
B 28-Mar-18
QCDC HSE Mngr. QC Mngr Const. Mngr. Proj. Dir.
Jaycy Yutuc Readolf Fedelin Rubenel Javier Ahmad Shibi Abdullah Hani
A 12-Feb-18
QCDC HSE Mngr. QC Mngr Const. Mngr. Proj. Dir.

Page | 1
 PROJECT / UNIT
JOB
Khurais Area Facilities Expansion & Satellite GOSP
032184
Project
PLANT LOCATION
Doc. No. 000-ZA-E-T09405
Khurais– SAUDI ARABIA

General Method Statement for Precast Concrete Rev. C 04-APRIL-18

General Method Statement for

Precast Concrete

Issued for Jaycy Yutuc Readolf Fedelin Rubenel Javier Ahmad Shibi Abdullah Hani
C 04-Apr-18
Review QCDC HSE Mngr. QC Mngr Const.Mngr. Proj. Dir.
Issued for Jaycy Yutuc Readolf Fedelin Rubenel Javier Ahmad Shibi Abdullah Hani
B 28-Mar-18
Review QCDC HSE Mngr. QC Mngr Const.Mngr. Proj. Dir.
Issued for JaycyYutuc Readolf Fedelin Rubenel Javier Ahmad Shibi Abdullah Hani
A 12-Feb-18
Review QCDC HSE Mngr. QC Mngr Const.Mngr. Proj. Dir.

Page | 2
 PROJECT / UNIT
JOB
Khurais Area Facilities Expansion & Satellite GOSP
032184
Project
PLANT LOCATION
Doc. No. 000-ZA-E-T09405
Khurais– SAUDI ARABIA

General Method Statement for Precast Concrete Rev. C 04-APRIL-18

Rev Description Prepared Checked Checked Approved Approved Date

Table of Contents
1. ENGINEERING DOCUMENTATION------------------------------------------------------------------- 4

1.1 Engineering Documentation--------------------------------------------------------------------

1.2 Foundation casting Sequence

2. SCOPE OF WORK & METHOD STATEMENTS----------------------------------------------------- 4

2.1 Scope of Work Summary

2.2 Formwork, Reinforcement, Embedded Items and Application of Bonding Agent
2.3 Concrete Placement
2.4 Curing and Stripping of Formwork
2.5 Surface Preparation and Bituminous Coating
2.6 Back filling and Compaction

3. DUTIES AND RESPONSIBILITIES (SAIPEM AND EACH SUBCONTRACTOR)-------------------- 6

4. APPLICABLE JOBSAFETY ANALYSIS------------------------------------------------------------------ 6

4.1 JSA for Transportation of People inside KHCPF------------------------------------------- 6

4.2 JSA for Loading & Unloading Material------------------------------------------------------- 6
4.3 JSA for Formwork Activity---------------------------------------------------------------------- 6
4.4 JSA for Rebar Work------------------------------------------------------------------------------- 7
4.5 JSA for Concrete Casting------------------------------------------------------------------------ 7
4.6 JSA for Concrete Repair--------------------------------------------------------------------------7
4.7 JSA for Bush Hammering of Concrete-------------------------------------------------------- 7
4.8 JSA for Grinding------------------------------------------------------------------------------------ 7
4.9 JSA for Concrete Protective Coating----------------------------------------------------------7
4.10 JSA for Backfilling----------------------------------------------------------------------------------7
4.11 GAP Analysis (to decide if any specific JSA required)------------------------------------ 7
Safety Requirements----------------------------------------------------------------------------- 7

5. QA / QC DOCUMENTATION--------------------------------------------------------------------------- 7

6. PLANNING------------------------------------------------------------------------------------------------- 7

6.1 Scheduling------------------------------------------------------------------------------------------- 7
6.2 Manpower-------------------------------------------------------------------------------------------8

Page | 3
 PROJECT / UNIT
JOB
Khurais Area Facilities Expansion & Satellite GOSP
032184
Project
PLANT LOCATION
Doc. No. 000-ZA-E-T09405
Khurais– SAUDI ARABIA

General Method Statement for Precast Concrete Rev. C 04-APRIL-18

6.3 Tools and Equipment----------------------------------------------------------------------------- 8

7. ATTACHMENT------------------------------------------------------------------------------------------------ 8
 JSA (JOB SAFETY ANALYSIS)
 DETAIL LIFTING TYPICAL HOOKS
 LOCATION PLAN

1. ENGINEERING DOCUMENTATION

Foundation’s Section Drawings

FOUNDATION CASTING SEQUENCE

Stage I-

 Base portion of foundations up to footing shall be pre casted in Gecat Precast yard with
lifting hooks and second placement is casted in place in Khcpf existing plant Brown Field
 Before installation of foundation, sub-grade shall be done as per SAES-A114
 Lean concrete (mud slab) shall be placed as per SAES-Q-001
 Construction joint is prepare by chipping of the top laitance layer

Stage II-

 The precast base portion is transported and placed in its exact location as per the IFC
Drawings on top of the placed blinding concrete.

Stage III-

 The Reinforcement, form work and embedded items (Anchor Bots, Pockets etc.,) are
installed as per the IFC drawings.
 Approved during agent shall be applied prior to the placement of concrete.
 Concrete for the pedestal portion is already place.

2. SCOPE OF WORK & METHOD STATEMENTS

2.1 SCOPE OF WORK SUMMARY

The purpose of this method statement is to describe and explain the needed work methods
to be developed during precast for Khurais Area Facilities Expansion & Satellite GOSP
Project.

Page | 4
 PROJECT / UNIT
JOB
Khurais Area Facilities Expansion & Satellite GOSP
032184
Project
PLANT LOCATION
Doc. No. 000-ZA-E-T09405
Khurais– SAUDI ARABIA

General Method Statement for Precast Concrete Rev. C 04-APRIL-18

2.2 FORMWORK, REINFORCEMENT, EMBEDDED ITEMS AND APPLICATION OF BONDING

AGENT

 Formworks will be fabricated according to the IFC drawings.

 Forms and supports shall be properly designated to hold the weight of concrete impact
of concrete pouring.
 Form shall be made first and properly check for straightness, leveling and plumpness
prior to installation of reinforcement steel.
 Reinforcement steel shall be placed according to BBS schedule and IFC drawings.
 Spacing of PVC spacer shall be of SCH. 80 material shall be strong enough to hold the
rebar to its proper location. The minimum cover shall be provided as per table 2 of
SAES-Q-001.
 Lifting hooks shall be placed as per attached sketch i.e.,
 For the foundations up to 12 tons the Minimum dia of hook shall be 16 mm with
the development hook length ld=200mm
 For the foundations above 12 tons the Minimum dia of hook shall be 16 mm
with the development hook length ld=400mm
 Pocket for lifting hook shall be grouted after installation.
 All embedded items like Anchor bolts, plates and pockets etc., shall be properly place as
per the IFC drawings.
 Approved bonding agent shall be applied prior to the placement of concrete.

2.3 CONCRETE PLACEMENT

 Prior to concrete pouring, formwork shall be cleaned and free from any foreign
materials. Hot weather concreting works will be done as per the Saudi Aramco
specification and project procedures.
 For Concrete pouring RFI will be raised.
 Concrete will be placed in accordance to 09-SAMSS-097, SAES-Q-001, ACI301 and ACI
304R
 The type of cement shall be according to the approved SA specifications and general
notes.
 Consolidation of concrete shall be done by using vibrator and shall be compacted layer
by layer until reaching the final layer.
 The Finishing of concrete will be done as per the IFC drawing and project specification.

2.4 CURING AND STRIPPING OF FORMWORK

 After initial setting of concrete, exposed part will be covered with burlap and water and
then a plastic sheet.
 24 hours after pouring of concrete de-shuttering of external forms as per SAES-Q-001.

Page | 5
 PROJECT / UNIT
JOB
Khurais Area Facilities Expansion & Satellite GOSP
032184
Project
PLANT LOCATION
Doc. No. 000-ZA-E-T09405
Khurais– SAUDI ARABIA

General Method Statement for Precast Concrete Rev. C 04-APRIL-18

 Concrete will be continuously water cured for 7 days in accordance to the Saudi Aramco
Standards and project specifications.

2.4.1 TRANSPORTATION and ERECTION

 Prior to first lifting of the precast item, the minimum compressive strength shall be
70% of the strength of the concrete type required at the related IFC Drawings.
 Every precast item shall be lifted using applicable capacity of mobile cranes.
 All lifting tools, equipment, and personnel for lifting shall have certificate from
approved third party.
 Certified riggers shall be assigning for lifting activities. Utmost care shall be taken
while loading, transportation at site.
 Prior to lean concrete FDT shall be done for sub grade as per SAES-A-114
 Lean concrete or clean sand with plastic will be placed according to IFC Drawings
 Precast item shall be placed to its precise locations cording o the survey mark and
elevations.

2.5 SURFACE PREPARATION

 All defects on concrete surface shall be properly repaired as per related MS for Concrete
repair.
 Concrete surface shall be free from laitance, contaminants and others adhered
compounds on the concrete like the curing agents.
 Surface preparation, coating application and selection, for concrete surface shall be as
per SAES-H-003.

2.6 BACKFILLING AND COMPACTION

 Final coating shall be inspected before backfilling.

 Backfilling shall be done as per SAES-A-114

3. DUTIES AND RESPONSIBILITIES

PM – Project Manager – Overall Responsibility of PM to organize the resource to perform

construction activity as per project specification in compliance with Quality, Schedule and
HSE requirement.

CM – Construction Manager – it is the responsibility of CM that construction activities are

executed according to the relevant project specification, in compliance with Quality,
Schedule and HSE requirement.

DE – Discipline Engineer – will ensure that the works are performed safely as per the latest
approved drawings and specifications.

Page | 6
 PROJECT / UNIT
JOB
Khurais Area Facilities Expansion & Satellite GOSP
032184
Project
PLANT LOCATION
Doc. No. 000-ZA-E-T09405
Khurais– SAUDI ARABIA

General Method Statement for Precast Concrete Rev. C 04-APRIL-18

DF – Discipline Foreman – will ensure that this crew has to follow the safe work procedure
and works are carried out as per the latest approved drawings.

QCI – Quality Control Inspector – will ensure that all the work is executed according to the
PQP and that the requirement of quality dossier is fulfilled.

Scaffold Supervisor (Aramco Certified) – will ensure that all the scaffolding activities
performed as per Aramco standard by his crew and also responsible to release the safe
working scaffold to the working team with proper tagging system and record.

HSE Supervision – will ensure that the works are performed safely as per the latest
Company requirements.

Construction Supervision – will ensure that the works are performed as per the latest
approved method statement and IFC drawings.

4. APPLICABLE JOB SAFETY ANALYSIS

4.1 JSA for Transportation of People inside KHCPF

4.2 JSA for Loading & Unloading Material
4.3 JSA for Formwork Activity
4.4 JSA for Rebar Work
4.5 JSA for Concrete Casting
4.6 JSA for Concrete Repair
4.7 JSA for Bush Hammering of Concrete
4.8 JSA for Grinding
4.9 JSA for Concrete Protective Coating
4.10 JSA for Backfilling

Safety Requirements
 Site Safety Supervisor shall carry out the safety site inspection to ensure that safety
requirements conform to safety work plan.
 Safety supervisor shall review the safety action plan and secure work permit if
necessary prior to start any activities. JSA will be strictly followed.
 Proper installation of barricades and signage shall be provided on swing areas of the
crane.
 All lifting tools, equipment, operators and riggers shall be verified by the third party
inspection.
 Proper use of PPE’s shall be observed during erection of precast items.
 Work supervision and safety coverage will be provided throughout the working
hours.

Page | 7
 PROJECT / UNIT
JOB
Khurais Area Facilities Expansion & Satellite GOSP
032184
Project
PLANT LOCATION
Doc. No. 000-ZA-E-T09405
Khurais– SAUDI ARABIA

General Method Statement for Precast Concrete Rev. C 04-APRIL-18

 Only certified riggers shall be used for lifting / erection of precast items.
 No lifting shall be done after sunset without permission or approval from ARAMCO.
 Proper access, barricade and signage shall be provided in all open excavation during
lifting operation

5. QA / QC DOCUMENTATION

All activities will be inspected and certified per

 SATIP-A-114-01 Rev.8 Earthwork - Site Preparation, Excavation and Backfill During

Construction final
 SATIP-Q-001-1 Rev.8 - Ready Mix Concrete Batch Plants and 3 rd Party Laboratory
Management final.
 SATIP-Q-001-2 Rev.8 – Cast-In-Place Portland Cement Concrete final.
 SATIP-H-003-01 Rev.8 – Coating Application on Concrete Surfaces final

6. PLANNING

6.1 SCHEDULING

As per work permit realize date.

6.2 Manpower

Item Qty
HSE Officer 2
Operator Excavator 2
Operator Truck 4
Workers 8
Operator Crane 1
Civil Surveyor 1
Foreman 3

6.3 Tools and Equipment

 Generator
 Air Compressor
 Vibrator
 Mobile Crane

Page | 8
 PROJECT / UNIT
JOB
Khurais Area Facilities Expansion & Satellite GOSP
032184
Project
PLANT LOCATION
Doc. No. 000-ZA-E-T09405
Khurais– SAUDI ARABIA

General Method Statement for Precast Concrete Rev. C 04-APRIL-18

 Concrete truck
 Concrete pump
 Loader
 Water Truck
 Trailer
 Boom Truck

7. ATTACHMENT

 JOB SAFETY ANALYSIS (JSA)

 DETAIL LIFTING TYPICAL HOOKS
 FACILITY PLOT PLAN

Page | 9