Document No. GE DIESEL LOCOMOTIVE Contract No.

530000024
FACTORY PROJECT,
GE-DLF-CBRE-SPCPL-QA-QC MARHOWRAH, BIHAR WMS –FABRICATION &
WMS-006 (Rev-0) ERECTION

WORK METHOD STATEMENT FOR

STRUCTUAL STEEL FABRICATION& ERECTION.

Revision No. Remarks Revised Date

By

0 Submitted by SPCPL 15-11-2016

APPROVAL STATUS

SHAPOORJI PALLONJI AND CO. PVT. LTD

Prepared By Checked By Approved By

PLANNING MANAGER QA/QC MANAGER PROJECT DIRECTOR
Sign:

Name:

Date:

Approved by CBRE

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 Document No. GE DIESEL LOCOMOTIVE Contract No. 530000024
FACTORY PROJECT,
GE-DLF-CBRE-SPCPL-QA-QC MARHOWRAH, BIHAR WMS –FABRICATION &
WMS-006 (Rev-0) ERECTION

Sign:

Name:

Date:

CONTENTS

1. SCOPE

2. PURPOSE

3. REFERENCES

4. ROLE & RESPONSIBILITIES

5. RAW MATERIALS

6. FABRICATION

7. MANPOWER

8. APPROVAL OF CUTTING PLAN & MARKING

9. BASE PLATE/CONNECTION PLATE DRILLING

10. SITE WELDING FOR STRUCTURAL STEEL

11. PROCEDURE QUALIFICATION

12. QUYALITY OF WELDING

13. SURFACE PREPARTION & PAINTING

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 Document No. GE DIESEL LOCOMOTIVE Contract No. 530000024
FACTORY PROJECT,
GE-DLF-CBRE-SPCPL-QA-QC MARHOWRAH, BIHAR WMS –FABRICATION &
WMS-006 (Rev-0) ERECTION

14. ERECTION

15. INSPECTION FOR FINAL ACCEPATANCE

16. SAFETY

17. ATTACHMENTS

1.0 SCOPE

 This Method Statement gives the stage wise activity to be carried

out for fabrication, erection and testing for structural steel work in
relation with GE-DLF Project.

2.0 PURPOSE

 To execute structural steel fabrication & erection work in a specific

and controlled manner with reference to technical/standard requirement.

3.0 REFERENCES

Following documents were used as reference for preparing this document;

 IS: 800 - Code of practice for general construction in Steel
 IS: 2062 - Weldable structural steel
 IS: 816 - Code of practice for use of metal arc welding for general
construction in mild steel.
 IS:1363 - Black Hexagonal Bolts, Nuts & Locknuts
 IS: 1367 - Technical supply conditions for threaded fasteners.
 IS:3757 - High strength friction grip bolts
 IS: 1161 - Steel tubes for structural purposes.
 IS: 5369 - General requirements for plain washers and lock washers.
 IS: 814 - Covered electrodes for metal arc welding of Structural (Part - I&II)
steel.

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 Document No. GE DIESEL LOCOMOTIVE Contract No. 530000024
FACTORY PROJECT,
GE-DLF-CBRE-SPCPL-QA-QC MARHOWRAH, BIHAR WMS –FABRICATION &
WMS-006 (Rev-0) ERECTION

 AWS D.1.1- American Welding Society

 IS-12483-Tolerance for erection of Steel Structure
 IS-7215- Tolerance for fabrication of steel structure
 IS-4000- Code of Practice for High Strength bolt in steel structure
 IS-822-Code of practice for inspection of welds
 IS-1477-Code of Practice for painting ferrous metal
 IS-812-Glossary tem related to welding & cutting of Material.
 IS-4923-Code for Hollow section
 IS-6610-Specification for Heavy Washer for steel structure
 IS-5372-Tapper washers for Channel
 IS-5374-Tapper washer for I beam
 IS-3063- Fasteners - Single coil rectangular section spring lock washers -
Specification
 IS-6649-Specification for Hardened and Tempered Washers for High
Strength Structural Bolts and Nuts.

4.0 ROLE & RESPONSIBILITIES:

 Project In charge: He shall be responsible to guide and give direction to
the entire site team to execute the job as mentioned in this WMS.
 Construction Manager: He shall be responsible for control, supervision
and implementation of this WMS at project site.
 Planning Engineer: Required Schedule, resources shall be well planned in
consultation with construction manager.
 QA/QC Engineer: He shall be responsible to carry out material approval/
field inspection/checking and facilitate in required test as per ITP & MTP.
 Site Engineer/Site Supervisor: He shall be responsible to carry out the
work as per drawing, specification and WMS.
 Safety Engineer: Shall facilitate in maintaining a good safe working
practices at site. Shall facilitate in risk analysis and required preventive
measures.
5.0 Raw Materials.

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 Document No. GE DIESEL LOCOMOTIVE Contract No. 530000024
FACTORY PROJECT,
GE-DLF-CBRE-SPCPL-QA-QC MARHOWRAH, BIHAR WMS –FABRICATION &
WMS-006 (Rev-0) ERECTION

 All Material shall be procured as per approved drawing & standard

requirement.

 Material for which test certificate not available or which test result do not

tally with relevant standard specification shall not be used .Material not

conforming the requirement shall be removed from site on immediate

effect.

 All Material shall be stored in such a way to avoid & prevent deterioration

and corrosion.

 Material shall be stored as per IS-4082.

 Dragging of steel shall not be carried out.

 Hot rolled plates should be defect free like pitting, rust and mechanically

damaged etc.

 Welding consumables are used as per ASME sec-ii/IS-814.

6.0 Fabrication:

 Fabrication Yard:

 The area for the fabrication yard shall be adequate for safe working of

workers, free movement of the material handling equipment, fast and

accurate positioning of the job on the machines and for positioning of the

machine near job.

 Material storage yard should be closest to the fabrication yard.

 A yard also shall be identified to store scrap material.

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 Document No. GE DIESEL LOCOMOTIVE Contract No. 530000024
FACTORY PROJECT,
GE-DLF-CBRE-SPCPL-QA-QC MARHOWRAH, BIHAR WMS –FABRICATION &
WMS-006 (Rev-0) ERECTION

 Layout of Welding Machine & Accessories:

 Welding Machine shall be installed in such a way at fabrication shop to

make leeway for easy movement of machinery.
 Welding Machine shall be lined up in a row with sufficient gap in between
to attend to maintenance and housekeeping.
 The power distribution board shall be single/three phase power sockets
and all safety apparatuses such as earthing, ELCB, fuses etc and located
near to the machine so that power cable do not run in the working area.
 Two numbers of independent earth connections shall be provided to the
power distribution board.
 The electric power to the hand held electrical machine shall be only
through industrial power sockets & pin.

 Process of Fabrication:

Following general check points shall be considered for fabrication in

charge/Engineer;

 Requirement of Approved Structural GA & Fabrications Drawing

 Monitoring of the approved fabrication drawings released in correct

sequence

 Receipt of Structural steel items in time and in adequate quantities as per

site fabrication/erection requirements

 Cutting drawings for the plates to be drafted and should be approved prior

to implementation onsite in order to control and establish the wastage of

material.

 Selection of suitable lengths of sections to minimize additional joints as

well as to minimize wastage

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 Document No. GE DIESEL LOCOMOTIVE Contract No. 530000024
FACTORY PROJECT,
GE-DLF-CBRE-SPCPL-QA-QC MARHOWRAH, BIHAR WMS –FABRICATION &
WMS-006 (Rev-0) ERECTION

 Location of the field joints to be provided as per the material receipt and

the joint should be approved from concern engineer/consultant.

 Ensure completion of Pre work on the shop floor for field spliced joints to

minimize crane hours during erection.

 Monitor the quality of work as per MTP & ITP of structural steel fabrication

and erection.

 Ensure that only qualified welders are performing the welding operation.

 Approved grade of electrodes, filler wires, fluxes alone are brought and

used in the work. Non approved electrode if procured, same shall be

removed from site.

 Review radiography interpretation reports and identify the repeated

defects in the welds, noticed of a particular welder and suggest remedial

measures.

 Checks of the fabricated items with reference to the approved drawings to

ensure straightness, dimensional correctness and visual defects in weld

joints, bolting connections wrapping etc.

7.0 Manpower:

For fabrication & erection of structural steel, the following workers are
required to be deployed. The number of worker in each category will
depend on the work load.
 Fabrication In charge/Engineer
 Drafting Engineer/detailer
 Material Planner

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 Document No. GE DIESEL LOCOMOTIVE Contract No. 530000024
FACTORY PROJECT,
GE-DLF-CBRE-SPCPL-QA-QC MARHOWRAH, BIHAR WMS –FABRICATION &
WMS-006 (Rev-0) ERECTION

 Supervisors
 Fabricator
 Fitters
 Welders
 Markers(For Punching)
 Erection Foreman
 Riggers
 Gas Cutters
 Grinders
 Helpers
 Crane Operators
 Heavy Vehicle drivers
 Unskilled Labours
 Manpower for special works

8.0 Approval of Cutting Plan & Marking.

 Based on approved cutting plan, cutting layout for each thickness

shall be prepared.
 In cutting layout, all identification details shall be mentioned for
traceability.
 Before starting marking and cutting, thickness of every plate are
verified by marking fitter with suitable instrument gas cutting
process
 Manual marking is required for oxy-Acetylene gas cutting process
 During cutting, suitable cutting allowances shall be taken according
to plate thickness.
 The time of marking raw material identification, heat number & coil
no to be recorded with respect to individual mark.
 If required, straightening to be done by cold bending process.
 Cutting shall be done with approved type of gas only.
 For continuous cutting, locking is to be done to avoid distortion.
 Cutting nozzle shall be used as per cutting thickness requirement.
 After cutting, burn, slag etc are to be removed by grinding.
 SMAW shall not be used for cutting.

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 Document No. GE DIESEL LOCOMOTIVE Contract No. 530000024
FACTORY PROJECT,
GE-DLF-CBRE-SPCPL-QA-QC MARHOWRAH, BIHAR WMS –FABRICATION &
WMS-006 (Rev-0) ERECTION

 Gas cutting shall not be used for hollow section.

 All cutting edges shall be made smooth by grinding.

9.0 Base Plate/Connection Plate drilling:

 Base Plate & Connection plate hole marking is to be done as per

shop drawing requirement.
 After hole marking required identification are marked on connection
plate with permanent marker.
 If plate quantity for same part mark is too much then templates are
made for hole marking.
 After drilling every connection plate are checked by operator and
engineer to ensure correct drilling as per requirement.

 Base Plate/Connection Plate Setup:

 Base Plate & other connection plate shall be fitted by position

tacking as per drawing requirement.
 Welding joints shall be cleaned before doing setup for good
quality welding.
 At setup station, each and every part mark are marked with metal
die letter for identification.

10.0 Site Welding of structural steel:

Following aspects shall be critically examined before allowing welding of

the structural steel members;
 The number of welding machines and accessories such as
grinding machines, cutting torches, electrode oven etc deployed at
site for production of the welded components on the shop floor
should be commensurate with the demand for erection in the
correct sequence.
 Power tools on their arrival shall be checked and tagged prior to
use their actual use at site.
 The welders are to be qualified as per IS-817/IS-7318. The position
of weld test piece has to be conducted at site.

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 Document No. GE DIESEL LOCOMOTIVE Contract No. 530000024
FACTORY PROJECT,
GE-DLF-CBRE-SPCPL-QA-QC MARHOWRAH, BIHAR WMS –FABRICATION &
WMS-006 (Rev-0) ERECTION

 The approved test piece shall be test for mechanical test as

required by relevant standard specification.
 If radiography quality welding is specified in the approved drawing,
the test piece shall be examined by radiograph for the quality of
weld performed by welder.

11. Procedure Qualification:

 Welding Procedure Specification (WPS) and Procedure

Qualification record (PQR) shall be preapred to determine
whether the weldment proposed for fabrication is capable for
resulting in a good and sound quality weld with the mechanical;
strength, chemical and metallurgical properties to the specified
values.
 Welding Procedure Specification is to list all the essential and non
essential variables in each process that are included under the
particular procedure specification before test.
 WPS and PQR shall be prepared and approved from
client/consultant prior to work.
 After successful completion of WPS & PQR the welder are tested
for the skill and ability to perform welding works in line with
approved PQR.
 The welder shall perform on a test coupon of either a plate or
pipe. The test coupon shall be subjected to non destructive tests
such as radiography or magnetic particle test depending on the
selected degree of soundness of the fabrication and conduct
mechanical test as derived in PQR shall be adopted.
 After successful WPQ, the welder shall be permitted to certain
welding positions and to certain wall thickness/plate thickness
based on PQR parameter.
 The various test position in welds are 1G,2G,3G,[Link] shall be
noted that a welder qualified for the plate groove 4G position may
be permitted to perform plate groove& plate fillet weld in all
positions.
 A welder qualified for the plate grooves 2G position may be
permitted to weld 2G, 1G and fillet H&V only.

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 Document No. GE DIESEL LOCOMOTIVE Contract No. 530000024
FACTORY PROJECT,
GE-DLF-CBRE-SPCPL-QA-QC MARHOWRAH, BIHAR WMS –FABRICATION &
WMS-006 (Rev-0) ERECTION

 A welder qualified in 3F position can weld in all fillet weld positions

but for overhead fillet weld.
 A welder qualified for pipe groove for 5F position may be
permitted to weld in all position except 6G or 5G.

12. Quality of Welding

 Unequal leg during fillet welding, concavity, porosity, undercut

shall be avoided during welding.
 Weld shall be inspected for flaws by following methods;
i. Magnetic Particle Test/Liquid Penetration Test
(IS-5334 & IS-3568)
ii. Radiography Test(IS-1182 & IS-2595)

 Any defect if occurred during testing, same shall be rectified as

per standard requirement.

13. Surface Preparation & Painting

 Grit Blasting shall be carried out for plates and as per ISO-8501-
1 with the help of DG Set, Air Spray gun & Air Compressor.
 In order to achieve maximum durability, blast cleaning shall be
done to ensure that clean and dry surface free from oil, grease,
rust etc are achieved.
 Blast cleaning shall not be done during humid weather condition
having humidity exceeding 85%.
 All ferrous surface shall be mechanically cleaned.
 The closed painting shall specify the required quality of
mechanical cleaning in accordance with the pictorial abstraction
in relevant standard .The prepared surface shall be finally

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 Document No. GE DIESEL LOCOMOTIVE Contract No. 530000024
FACTORY PROJECT,
GE-DLF-CBRE-SPCPL-QA-QC MARHOWRAH, BIHAR WMS –FABRICATION &
WMS-006 (Rev-0) ERECTION

brushed cleaned of all disintegrated scale and rust, but shall not
be burnished by excessive wire brushing.
 Priming should be done before any deterioration of the prepared
surface occurs, preferably within 4hrs of completion of
preparation
 All steel work shall be cleaned off loose mill scale, rust, dirt and
other foreign material as required/mentioned in the drawing
requirement.
 All nuts, bolts, washer shall be cleaned and dipped in boiled
linseed oil.
 Unless specified otherwise, all surfaces inaccessible after
bolting or intermittent welding shall be given two coats of primer
before assembly.
 Welds and adjacent parent material shall not be painted prior to
de slagging and approval.
 The painting shall meet the fire, durability and aesthetic
requirements.
 Approved brand of painting shall be used for work and DFT shall
be checked through Elko meter.

14. Erection:

 The Fabricated Members should have erection identifying

marks which are generally indicated in erection marking
drawing.
 For long sections, the splicing area to be marked with punch
points for center line in both directions to match the alignment
erection at site.
 Normally erection cleat are welded to heavier section, so that
during erection the member is placed in its intended location

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 Document No. GE DIESEL LOCOMOTIVE Contract No. 530000024
FACTORY PROJECT,
GE-DLF-CBRE-SPCPL-QA-QC MARHOWRAH, BIHAR WMS –FABRICATION &
WMS-006 (Rev-0) ERECTION

either the temporary erection bolts are fitted or the member is

tack welded to the erection cleat.
 For the spliced joints, particularly in the columns, half length of
the splice plates are normally welded to the bottom segment of
the column and the remaining half of the splice plate meant for
joining the top segment of the column is provided with holes for
bolting top segment.
 The top segment of the splice joint depending on the type of
splice may either be using bolts and nut connections or by
welding.
 Level and alignment of the column shall be checked using
heavy duty plumb bobs fixed at 90degree to each other tied by
piano wire.
 Correction for elevation and verticality can be accomplished
with help of packer /shim plates between the base plate and
RCC foundation.
 For tall columns, survey instruments shall be used for checking.
 While erecting tall columns, to have access to the top it is an
accepted practice to weld cage ladder on one face of the
column for persons to climb.
 Grouting of the base columns shall be after a section of work
has been erected and aligned.
 Grouting of individual column after its erection shall be avoided
as it shall not be possible to make minor adjustment in the
alignment in the columns already grouted, while aligning group
of adjacent columns.
 In case of normal bolted connections, taper/flat/spring washers
shall be used as necessary
 In case of high strength friction grip bolt, hardened washer &
spring washer shall be used under the nuts or bolt whichever
are turned to tighten the bolt.
 The length of the bolt shall be such that minimum two thread of
the bolts projects beyond the nuts.
 In case of high strength friction grip bolt, such projection shall
be minimum three threads.

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 Document No. GE DIESEL LOCOMOTIVE Contract No. 530000024
FACTORY PROJECT,
GE-DLF-CBRE-SPCPL-QA-QC MARHOWRAH, BIHAR WMS –FABRICATION &
WMS-006 (Rev-0) ERECTION

 In all cases only the unthreaded position of the bolt/stud shall

have bearing on the member assembled.

15. Inspection for Final Acceptance:

 Final inspection shall be carried out after completion of
fabrication, erection and grouting of structure for acceptance.

16. Safety:
 SWP & HIRA shall be prepared and approved from CBRE prior to start of
work.
 As structural fabrication involves heavy welding and many personnel have
to work in a congested shop floor. This often results in injuries to the
personnel. The layout shall be corrected/ adjusted accordingly for safe
working.
 Inadvertent touching with bare hands to the welded joints shall be
avoided.
 Grinding/Cutting wheels without guard shall not be allowed for work.
 Cris crossing of the power cables that too with many joints
improper/broken earthing of the power distribution boards/panels shall not
be allowed at work location.
 Electric Shock Proof hand gloves to be used during handling of electrical
tools.
 Exposure to radiography source shall not be entertained to any workers.
 Back arrester should be provided for cutting set.
 Fire extinguisher and sand filled buckets shall be ensured at welding &
cutting location.
 Hot work Permit shall be taken from concern authority or as per
requirements.,
 Power supply to all electrical equipments & toll shall only be through rated
ELCB.
 Power cables and welding cables should be free from joints at fabrication
shop/yard.

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 Document No. GE DIESEL LOCOMOTIVE Contract No. 530000024
FACTORY PROJECT,
GE-DLF-CBRE-SPCPL-QA-QC MARHOWRAH, BIHAR WMS –FABRICATION &
WMS-006 (Rev-0) ERECTION

 Temporary lifting lug welded with any member should have adequate
strength and weld length to cater to the load with factor of safety of 5.
 Periodical check should be carried out to ensure good condition of
electrode holders. hand held tools, oxy acetylene gas regulator, cutting
torches and gas hoses etc.
 Ensure proper slinging of the member to avoid sliding/jerking of the load
during erection.
 Approved erection/rigging plan shall be prepared and approved from
necessary authority prior to start of erection.
 Avoid erection during rain, heavy winds & night hours.
 Structural member like columns, trusses, and lattice girder etc shall be
provided with adequate number of guy ropes to hold them till alignment
final bolting and lifting is completed.
 Check adequacy of erection cleats(Especially if not shown on the
drawings).
 Ensure that erection bolts are reasonably tight and not kept loose.
 Cordon of the erection and fabrication areas to restrict movement of
unauthorized persons.
 SPCPL-Safety in charge shall review the specified safety requirement
mentioned in this WMS and additional comments can be incorporated for
further improvement.

17. Attachments
 Inspection & Test Plan for Structural fabrication & erection
 Material Test Plan for Structural fabrication & erection

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