STEEL INFRA SOLUTION PRIVATE LIMITED

DIAL - IGI AIRPORT PHASE-3A

DEVELOPMENT WORKS
New Delhi

Doc Title Method Statement for Fabrication of Steel Structure

Works Quality Management System

SUBMISSION OF METHOD
STATEMENT FOR STRUCTURAL
STEEL FABRICATION WORKS

PREPARED BY REVIEWED BY APPROVED BY

SISCOL L&T DIAL

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 STEEL INFRA SOLUTION PRIVATE LIMITED

DIAL - IGI AIRPORT PHASE-3A

DEVELOPMENT WORKS
New Delhi

Doc Title Method Statement for Fabrication of Steel Structure

Works Quality Management System

CONTENTS

S.NO TITLE PAGE No.

i Title Sheet 01

ii Contents 02

1 Scope of Work 03

2 Access/Egress 03

3 Technical References 03 - 04

4 Responsibilities 05 – 09

5 Emergency Preparedness 09

6 Storage & Stacking of Material 09

7 Safety measures & Precautions 10

8 Plant and Equipment 10 - 11

9 Trainings 11 – 12

10 Location Workmanship 12

11 Materials 12

12 Interdepartmental Coordination 12 - 13

13 Sequence/Method of Work 13 – 22

14 Tolerance 22

15 Inspection certificates 22

16 Quality assurance & control 22

17 Dispatch 23

Page 2 of 23
 STEEL INFRA SOLUTION PRIVATE LIMITED

DIAL - IGI AIRPORT PHASE-3A

DEVELOPMENT WORKS
New Delhi

Doc Title Method Statement for Fabrication of Steel Structure

Works Quality Management System

1.0 SCOPE OF WORK:

Propose of this Method Statement is to describe the sequence of activities

which will be followed to execute the Steel Structure fabrication works,
testing, including unloading of the raw materials and loading of fabricated
materials to dispatch at DIAL-IGI AIRPORT PHASE-3A DEVELOPMENT
Project.

2.0 ACCESS / EGRESS:

• Proper access and egress will be ensured before and till completion of
work.
• Temporary signage will be provided at access and egress. Approaches
and exits shall be clearly defined by barricades and warning/caution
signs.
• Proper illumination and ventilation as per SH&E 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.

3.0 TECHNICAL REFERENCES:

• IS-814 - Covered electrodes for metal arc welding of structural steels:

IS814
• (Part 1) -1974 Part 1 for welding products other than sheets (fourth
revision)
• IS-1278-1972 -Filler rods and wires for gas welding (second revision)
• IS-3757-1985 - HSFG Bolts
• IS-2062-2011 - Hot rolled Medium and High tensile structural steel
(Seventh revision) Grade E-350

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 STEEL INFRA SOLUTION PRIVATE LIMITED

DIAL - IGI AIRPORT PHASE-3A

DEVELOPMENT WORKS
New Delhi

Doc Title Method Statement for Fabrication of Steel Structure

Works Quality Management System

• IS-4000-1992 - Code of practice for assembly of structural joints using

HSFG Bolts
• IS-6649-1985 – Galvanized washers
• IS-7215-1974 -Tolerances for fabrication of steel structures
• IS – 823 - Code of procedure for manual metal arc welding of mild steel.
• IS-1181 – Qualifying test for metal arc welders.
• IS-1182 – Recommended practice for UT examination of full penetration
Butt joints.
• IS-3658 – Code of practice for LPT
• IS-5334 – Code of practice for MPT
• IS- 1477 – Code of practice for painting
• IS- 801 – Code of practice for use of Cold Forms
• AWS D1.1M- Structural Welding Code
• Approved Shop Drawings
• Project Technical Specifications
• Approved PQP
• Approved ITP
• Approved Fabrication GFC Drawings
• Approved WPS, PQR and WPR

4.0 RESPONSIBILITY:

PROJECT • Organize and manage all resources, field activities required to

DIRECTOR
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.

Page 4 of 23
 STEEL INFRA SOLUTION PRIVATE LIMITED

DIAL - IGI AIRPORT PHASE-3A

DEVELOPMENT WORKS
New Delhi

Doc Title Method Statement for Fabrication of Steel Structure

Works Quality Management System

• To ensure that all the equipment, tools and tackles required to

CHIEF PROJECT
MANAGER
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.

Page 5 of 23
 STEEL INFRA SOLUTION PRIVATE LIMITED

DIAL - IGI AIRPORT PHASE-3A

DEVELOPMENT WORKS
New Delhi

Doc Title Method Statement for Fabrication of Steel Structure

Works Quality Management System

• 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 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

Client.

Page 6 of 23
 STEEL INFRA SOLUTION PRIVATE LIMITED

DIAL - IGI AIRPORT PHASE-3A

DEVELOPMENT WORKS
New Delhi

Doc Title Method Statement for Fabrication of Steel Structure

Works Quality Management System

• 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 • Shall inspect in maintaining safe working environment &

INCHARGE
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 non compliance

• 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.

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 STEEL INFRA SOLUTION PRIVATE LIMITED

DIAL - IGI AIRPORT PHASE-3A

DEVELOPMENT WORKS
New Delhi

Doc Title Method Statement for Fabrication of Steel Structure

Works Quality Management System

P&M/ • Ensure availability of all statutory documents related to safe

ADMIN
INCHARGE
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 • Communicating with all site staff about the Quality

INCHARGE
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.

Shop 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.

Page 8 of 23
 STEEL INFRA SOLUTION PRIVATE LIMITED

DIAL - IGI AIRPORT PHASE-3A

DEVELOPMENT WORKS
New Delhi

Doc Title Method Statement for Fabrication of Steel Structure

Works Quality Management System

• Ensure all induction and training provided to workman related

to safety.

Store • EPCC 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.

5.0 EMERGENCY PREPAREDNESS:

• Emergency assembly point shall be provided near work place.

• Round the clock ambulance and first aider should be available at the site
with the required equipment’s and accessories.
• Fire extinguisher shall be provided near the work place.

6.0 STORAGE & STACKING OF MATERIAL:

• Stacking of all steel plates shall be proper, size and section wise.
• Material shall not be stacked directly on earth. It should be at-least
300mm 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 exceed from 2 mtrs.

7.0 SAFETY MEASURES AND PRECAUTIONS:

• 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.

Page 9 of 23
 STEEL INFRA SOLUTION PRIVATE LIMITED

DIAL - IGI AIRPORT PHASE-3A

DEVELOPMENT WORKS
New Delhi

Doc Title Method Statement for Fabrication of Steel Structure

Works Quality Management System

• 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 engineer
during activity.

8.0 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:
• High Speed CNC H Beam Drilling Line
• CNC Band Sawing & line Cross Conveyor
• CNC Cutting Machine with Plasma Flame Cutting Machine
• High speed CNC Drilling Machine
• Floor Type Boring/Milling Machine
• ABW 2100 Beam welding Machine
• Automatic Shot Blasting Machine
• Paint Booth System
• Lifting Chains

Page 10 of 23
 STEEL INFRA SOLUTION PRIVATE LIMITED

DIAL - IGI AIRPORT PHASE-3A

DEVELOPMENT WORKS
New Delhi

Doc Title Method Statement for Fabrication of Steel Structure

Works Quality Management System

• Lifting Clamps
• D-shackles
• Cutter/Hacksaw.
• Pug Cutting Machine
• Welding Machine.
• Grinding Machine.
• All Hand Tools like Hammer, Chisel, Gas heating torch, Spirit level,
measuring tape etc.
• Electrode Baking oven

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.

9.0 TRAINING:

• 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 logging
etc. shall be provided to all workman.
• General awareness training for Workers shall be organized by Quality
Department.

Page 11 of 23
 STEEL INFRA SOLUTION PRIVATE LIMITED

DIAL - IGI AIRPORT PHASE-3A

DEVELOPMENT WORKS
New Delhi

Doc Title Method Statement for Fabrication of Steel Structure

Works Quality Management System

10.0 LOCATION, WORKMANSHIP AND SITE CONDITION WORKING AREA:

• 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 and
suits to DAIL-Project nature and quantum of works.
• All steel work before and after fabrication shall be straight and free
from 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 fastening
shall not be used unless specified or approved by the Inspector.

11.0 MATERIALS:

All the materials used shall be as per Approved make list.

• Steel Plates.
• Rolled Section
• Welding Electrode/ Consumables

12.0 INTERDEPARTMENTAL COORDINATION:

• The EPCC Steel Structure team to sought clearance from EPCC MEP
and other departments for fabrication of Steel structure.
• The clearance/comments will be shared to EPCC Steel Structure team
as per their requirements by EPCC MEP and other departments and vice
versa.
• After the completion of the activity EPCC Site team has to seek for
internal clearance from EPCC QA/AC team.

Page 12 of 23
 STEEL INFRA SOLUTION PRIVATE LIMITED

DIAL - IGI AIRPORT PHASE-3A

DEVELOPMENT WORKS
New Delhi

Doc Title Method Statement for Fabrication of Steel Structure

Works Quality Management System

• The EPCC QA/QC team will issue clearance/comments to start painting

activity.
• Then the EPCC Site team raises inspection request of the activity to
PMC.
• Then the PMC will accord acceptance or comments if any for which IR
has been raised.
• The EPCC Site team has to comply the comments given by PMC and
fulfill the requirements if any.
• Then the EPCC QA/QC team and EPCC Site team will close the IR along
with PMC.

13.0 SEQUENCE/METHOD OF WORK:

13.1 Lifting and shifting of Structural Steel:

Fabricator 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
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.

Page 13 of 23
 STEEL INFRA SOLUTION PRIVATE LIMITED

DIAL - IGI AIRPORT PHASE-3A

DEVELOPMENT WORKS
New Delhi

Doc Title Method Statement for Fabrication of Steel Structure

Works Quality Management System

• 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-:

All lifting equipment like lifting chains, D-shackles, Lifting clamps will be as
per capacity with proper safety norms and proper test certificate from the
manufacturer/load test approved by authorised TPIA 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.

13.2 Storage & Protection:-

• Storage and stacking of material defined in Clause-6.

• 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.

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 STEEL INFRA SOLUTION PRIVATE LIMITED

DIAL - IGI AIRPORT PHASE-3A

DEVELOPMENT WORKS
New Delhi

Doc Title Method Statement for Fabrication of Steel Structure

Works Quality Management System

• Electrode shall be stored in Mother over as per requirement and

manufacturer’s recommendations.
• At field/shop, electrodes will be kept in portable ovens.

13.3 Material Inspection, approval & Traceability:-

• 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 Material
shall be matched with MTC.
• Reference of MTC shall be mentioned in respective invoice or visa-
versa.

13.4 Welder Qualification Approval and Traceability:-

• 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 pass 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 as
per approved WPS/PQR.

Page 15 of 23
 STEEL INFRA SOLUTION PRIVATE LIMITED

DIAL - IGI AIRPORT PHASE-3A

DEVELOPMENT WORKS
New Delhi

Doc Title Method Statement for Fabrication of Steel Structure

Works Quality Management System

13.5 Fabrication Procedure including steel marking and surface

preparation:-

• Suitable platform is required for assembly and Welding.

• Due to higher thickness of plates, Distortion will take place while

continuous welding process will going on to arrest all the distortion its
very essential to make suitable heavy support platform has to be placed
at 1meter distance to prevent distortion due to weld heat inputs so as to
keep plates in perfect level and sequence shall be carried out before
start the welding
• Before start of welding, the entire
member is locked properly by using
extra support to avoid distortion. After
completion of welding, when the
welded members cool down in
normal/room temperature the extra
support will be removed.

• For fit up of every new member,

cutting edges of the web will be removed and the fabrication platform
needs to be cleaned properly by removing all the spatters/slag/previous
welding spot.

Cutting& Marking:

Raw materials shall be marked and cut to size by shearing, saw cutting,
flame or plasma cutting and include the allowances such as cutting, grinding.

• Cutting Allowances shall be as follows-

1) Up to 6 mm: 2 mm
2) For 6-25 mm: 3 mm
3) For 25-63 mm: 4 mm
4) For 75-150 mm: 6-8 mm

• Flame cut edges shall be cleaned to remove slag. Uneven edges shall
be dressed by grinding.

• Gas cuts shall be smooth and regular in contour.

Page 16 of 23
 STEEL INFRA SOLUTION PRIVATE LIMITED

DIAL - IGI AIRPORT PHASE-3A

DEVELOPMENT WORKS
New Delhi

Doc Title Method Statement for Fabrication of Steel Structure

Works Quality Management System

• Cutting of plates by pug machine needs skilled and experienced

operators to maintain proper cutting edge. Also after one cut the next cut
will be started in other side of the plate to avoid distortion in cutting zone.

• Marking on steel shall be done in accordance of shop drawing and

cutting plan.

• Code of marking over fabricated member shall be as follows-

Drg. No. / Mark No. / Part No. / Weight / Heat No.

This marking on members shall be done by hard punch.

• Every separate member shall be plainly and permanently marked with

paint to show position and direction as necessary for each identification
and correct placing.
• Loose pieces of connection shall be attached to their respective
members.

Fit Out of assembly/sub-assemblies.

a) Fitting shall be carried out after ensuring removal of burrs, notches, grinding of
edges wherever required.
b) Identification markings for mark no., drawing no. and other shall be carried out
as per the drawing/specification/approved QAP.
c) After completion of the fit out, Production shall check the job/assy./sub-
assembly for completeness, physical condition to ensure absence of surface
defects. Production will also record the name of the fitter(s) for feedback,
improvement and skill level assessment.
d) IQC-Fit Up shall carry out inspection as per the drawing (drawing should have
good for manufacturing stamping by PPC/PMG- to ensure that that it is
pertinent issue of the drawing). IQC shall prepare dimensional report and
record dimensions, orientation of the child parts, correct weld preparation etc.
e) After completion of rectification, assembly/sub-assembly shall be
cleared/moved to welding section. Welding supervisor shall carry out welding
using qualified welders and the procedures which are appropriate to achieve
desired welding quality.

Page 17 of 23
 STEEL INFRA SOLUTION PRIVATE LIMITED

DIAL - IGI AIRPORT PHASE-3A

DEVELOPMENT WORKS
New Delhi

Doc Title Method Statement for Fabrication of Steel Structure

Works Quality Management System

Punching, Drilling and Reaming:

For Grade 4.6 bolts, holes in material up to 16mm may be punched, drilled
full size or sub punched 3mm undersize and reamed to size. Punching is not
permitted in plates thicker than 16mm. For Grade 8.8/10.9 bolts, holes must
not be punched. The hole diameter shall be 2mm larger than the bolt
diameter for bolts not exceeding 24mm and not more than 3mm larger for
greater diameter bolts. Holes in base plates shall not be more than 6mm
larger than anchor bolt. A special oversize 4mm minimum thick washer shall
be provided with these oversize holes or as specified in approved drawings.

Pre-heating:

• Fit-ups of members will be carried out by qualified fitters under the

supervision of Fit-up
supervisors as per
ITP/QAP/TS/Dwg. There will be
inspection by QC team as per
ITP/QAP/TS/Dwg and after
clearance welding will be
started.
• Preheat and Interpass Temperatures: Parts to be welded shall be
preheated by means of gas flames, or other means to bring to the
specified preheat temperature the full thickness of the base metal for a
distance equal to the thickness of the part being welded, but not less
than 75mm from the point of welding. Welding preheat temperatures
shall be in accordance with AWS D1.1 and checked by thermal chalk or
Temperature Gun.

Page 18 of 23
 STEEL INFRA SOLUTION PRIVATE LIMITED

DIAL - IGI AIRPORT PHASE-3A

DEVELOPMENT WORKS
New Delhi

Doc Title Method Statement for Fabrication of Steel Structure

Works Quality Management System

• The root run will be made by GMAW/FCAW for full fusion and checked
soundness of weld by NDT make sure that there is no defect in the root.
After that, SAW will be used for filling the groove in multi-layer. In multi-
layer welding slags, spatter, other impurities etc. on each completed
weld shall be removed prior to the start of next layer.
• For pre heating of long section, series of burners fitted in a suitable frame
shall be used to maintain regular heating in total area at a time. LPG will
be used as fuel for heating burner.
• Thermal chalk or temperature Gun will be used to check the required
temperature when heating process is going on.
13.6 WPS and PQR will be submitted for approval for following welding process-

1. SMAW
2. GMAW
3. SMAW + SAW

Removal of Slags:

All slag, scale and other inclusions shall be removed and the adjacent metal
brushed clean not only from the edges to be welded, but also from each pass
or layer before the deposition of subsequent passes or layers. This
requirement shall apply not only to successive layers but also to successive
beads and to the crater area when welding is resumed after any interruption.
The steelwork at welded joints shall not be painted or otherwise treated
externally until the joints have been completed, slag, spatter, rust, scale, oil
and dirt have been removed, the surface has been prepared as specified
under "Corrosion Protection", and the joint has been inspected and approved
by the Inspector.

Page 19 of 23
 STEEL INFRA SOLUTION PRIVATE LIMITED

DIAL - IGI AIRPORT PHASE-3A

DEVELOPMENT WORKS
New Delhi

Doc Title Method Statement for Fabrication of Steel Structure

Works Quality Management System

Inspection & Testing:

• The stage inspection shall be carried out as per approved ITP.

• The dimensions of weld structural members shall be within the project
specification (AWS D1.1M)
Blasting:

a) The cleared jobs shall be moved to the blasting machine/manual blasting

depending upon the size of the jobs. Blasting shall be carried out and the
parameters like time of blasting, finish achieved, visual check for
completeness etc. shall be done by Blasting operator/supervisor in the
register. IQC Welding shall carry out one more check at this stage and ensure
that the jobs is clear of scale, rust, profile and finish is satisfactory, any leftover
welding, grinding, burrs, notches are taken care of before giving clearance for
primer/painting. This inspection shall be completed in 10-20 minutes of time
to allow adequate time for primer application of the job.
b) IQC-Blasting area will put up a green sticker ÓK’ on the job and hand over the
part mark list to the painting/blasting supervisor. Painting supervisor will only
move such jobs to painting area for primer application which has OK sticker
and as per the cleared part mark list.
c) Non-conforming jobs list shall be provided to Head Operations for getting
these attended, reworked. These shall be re-inspected by IQC before these
are moved to the paining area and accompany the cleared part mark list as
well as identified sticker.
Painting, metalizing, stencilling and Identification Marking:

a) Painting supervisor shall ensure that primer coating is done within 4 hours
during raining days and within 4-6 hours on other days. Painting supervisor
shall maintain project wise record of primer, MIO and final coat paint opening
stock, paint drawn during the shift and the closing stock. In case, paint is
required to be issued from Stores, Painting supervisor shall fill up the
requisition and get it signed from PMG project and update records.
b) Paint supervisor shall also monitor paint mixing and its right proportion,
quantity mixed, pot life for cutting down on wastage. He will also maintain the
part mark list along with drawing no and shall provide this to PMG to calculate
surface area and monitoring of the Paint Loss Factor’’

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 STEEL INFRA SOLUTION PRIVATE LIMITED

DIAL - IGI AIRPORT PHASE-3A

DEVELOPMENT WORKS
New Delhi

Doc Title Method Statement for Fabrication of Steel Structure

Works Quality Management System

c) For the outsourced jobs, the concerned planning Engineer will maintain the
above records of paint consumed, day wise, sub-con wise along with list of
parts and surface area painted (separately for primer, MIO and final coat) to
calculate Paint Loss factor and generation of MIRs.
d) Record of temperature, humidity (dry and wet bulb temp) shall be recorded at
least 2 times in a shift, along with curing time given to each part mark by the
Paint Supervisor.
e) WFT shall be checked by the concerned painter to control the process for final
painting and DFT.
f) Stencilling and marking shall be completed and offered to IQC. IQC will check
for visual defects, paint thickness, DFT etc. and shall co-ordinate with client
for clearance. The list of the cleared jobs shall be provided to Paint shop as
well as Logistics team to shift and plan for dispatch.
g) Bed area cleaning and final touch up shall be done by the Logistics Team and
PDI shall be done by IQC- Paint & Logistics prior to dispatch.
h) Logistics will not dispatch without PDI clearance and shall ensure proper
loading, lashing, rubberized padding to ensure safe and quality transportation.
Visual Management:

Stickers for Hold/OK/PDI processes, which provides in-situ communication to

the stakeholders the job’s status:

Following inspection offer formats cum checklists will be implemented:

• Incoming Raw Material Inspection Report

• Fit up Inspection Report

Page 21 of 23
 STEEL INFRA SOLUTION PRIVATE LIMITED

DIAL - IGI AIRPORT PHASE-3A

DEVELOPMENT WORKS
New Delhi

Doc Title Method Statement for Fabrication of Steel Structure

Works Quality Management System

• Welding Inspection Report

• NDT Reports
• Surface Preparation & Painting Inspection Report
• Pre-Despatch Inspection Report

14.0 TOLERANCES

Raw Materials

• Tolerances of Raw Material of MS Plate & Rolled Sections shall be as

per IS: 2062
• Tolerance of Hollow Sections shall be as per IS 4923.

15.0 INSPECTION CERTIFICATE

• The Testing Agency/Inspector shall carry out all the shop inspections,
non-destructive or destructive testing specified herein, review all test
certificates and materials, undertake full-time inspections of the
fabrication works on site, supervise welder’s qualification tests, inspect
and test surface. The Testing Agency/Inspector shall submit certificates
for the various sections of the work directly to the Employer or Engineer’s
Representative.

16.0 QUALITY ASSURANCE & CONTROL

• Ensure necessary testing/checking is done as per approved ITP. Daily

records of quality checks shall be maintained.

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 STEEL INFRA SOLUTION PRIVATE LIMITED

DIAL - IGI AIRPORT PHASE-3A

DEVELOPMENT WORKS
New Delhi

Doc Title Method Statement for Fabrication of Steel Structure

Works Quality Management System

17.0 DISPATCH:

All items shall be suitably packed in case these are to be dispatched from
the fabrication shop to actual site of erection so that any damages/distortion
can be avoided during transit. If necessary projected parts shall be
temporarily braced to avoid warping during transit.

Page 23 of 23