EXW-P023-0003-QM-LAJ-FO-00003 Rev.

CF

Table of Contents
1. SCOPE..................................................................................................................................... 3
2. REFERENCE ........................................................................................................................... 3
3. DEFINITION ............................................................................................................................. 3
4. RESPONSIBILITIES ................................................................................................................ 4
5. RESOURCES ........................................................................................................................ 11
5.1 Manpower ........................................................................................................................ 11
5.2 Plant Equipment .............................................................................................................. 11
5.3 Materials .......................................................................................................................... 12
5.4 Process Involved ............................................................................................................. 13
6. HEALTH/ SAFETY/ ENVIRONMETAL PROTECTION ......................................................... 14
6.1 Health and Safety ............................................................................................................ 14
6.1.1 Emergency Response ............................................................................................ 14
6.2 Fabrication ....................................................................................................................... 14
6.2.1 Protective & Safety Equipment ............................................................................. 14
6.2.2 Procedure ................................................................................................................ 14
7. SEQUENCE OF WORKS ...................................................................................................... 16
7.1 Area of the works ............................................................................................................. 16
7.2 Programmed / Timeline of the works ............................................................................... 16
7.3 Sequence of works for Fabrication Process .................................................................... 16
7.3.1 Suitable Raw Materials .......................................................................................... 16
7.3.2 Preparation of Base plate/Flanges/Web/Connection Plates & Others .............. 16
7.3.3 Visual Inspection and Repair with Edge Flame Cut Edge .................................. 20
7.3.4 Fitting (Assembly & Web to Flange Joint) ........................................................... 20
7.3.5 Fitting Assembly (Component Tack Welding) ..................................................... 23
7.3.6 Final Welding (Repair / Correction) ...................................................................... 25
7.3.7 Non-Dectructive Testing (NDT) ............................................................................. 30
7.4 Environmental Issues ...................................................................................................... 35
7.4.1 Impacts .................................................................................................................... 35
7.4.2 Mitigation Measures ............................................................................................... 35
8. Appendix: ENVIRONMENTAL RISK ASSESSMENT .......................................................... 36
9. APPENDIX ............................................................................................................................. 39

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 1. SCOPE

The purpose of this Method Statement is to describe the methodology for the structure steel
fabrication works for the Design & Construct of Al Tamim Air Base Project with contract No.C‐108‐
1 at Dukhan, State of Qatar. The works shall be constructed by M/s Bahadir Construction.

This is also developed to make concerned person familiarized with the sequence of activities,
utilizations of resources and relevant risk assessment to meet project specifications & contractual
obligations.

2. REFERENCE

 Project Specifications
 Project Drawings
 QCS 2014
 American Welding Society(AWS D1.1/D1.1M:2010)
 BSEN ISO 15614‐1/BS EN ISO 15609‐1
 ASTM Standard for Structural Steel Fabrication

3. DEFINITION

CLIENT (QECE) : Qatar Emiri Corps of Engineers Wing‐5

QCS : Qatar Construction Specifications

HSE : Health, Safety & Environment

MOE : Ministry Of Environment

MOI : Ministry Of Interior

IR : Inspection Request

QA/QC : Quality Control / Quality Assurance

BAH : M/s Bahadir Construction

PQP : Project Quality Plan

MS : Method Statement

AFC : Approved For Construction

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 4. RESPONSIBILITIES

Project Manager
 Overall responsible for implementation of the company management systems, Quality
policies, Safety policies and procedures in line with Project Specification, Drawings, Method
Statements, etc.

 Prepare and monitor progress as per approved scheduled for the whole project duration in
coordination with the site team.

Construction Manager
 Organize the site so that work is carried out to the required specifications with a minimum
risk to men, equipment and materials.

 Adhere to the Project Specific Quality Management Program, HSE Requirements, Method
Statements, Project Specification and Drawings.

QA/QC Manager
 Identify the Projects Specific Quality Requirements, Develop the Project Specific Quality Plan
(Project Quality Plan), Inspection and Test Plan (ITP), Project Specific Procedures, Checklist
and Quality Control Forms and ensure effective implementation of the same.

 Resolving day to day Quality issues with Client or Client Representative.

 Organize Project Quality Management Review Meetings and follow up implementation of

the Management decisions/ recommendations concerning Quality of work and costumer
focus.

 Ensure compliance with applicable National and International Standards as well as relevant
statutory requirements.

 Monitoring/Evaluate the performance in terms of Quality requirements for Sub‐Contractor.

QA/QC Engineer
 Responsible for the work entire Quality Assurance, Quality Control & inspection programs.

 Produce all Quality related documents & necessary quality reports as requested.

 Provide written procedures & to coordinate in formalizing the Method Statement with the
Project manager/Site Engineers to describe the job specific procedure for each
stage/activity.

 Direct QC Inspector on site.

 Monitor performance of site team to ensure compliance with quality procedure.

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 HSE Manager
 Responsible for entire HSE matters and reviewing Hazard Identification (HI), Risk Assessment
(RA) in line with Method Statements for particular activity.
 Liaison with Client or Client Representative for HSE issues.

 Monitoring the HSE requirements as per Project Specifications and Client or Client
Representative’s requirements.

HSE Officer
 Ensure that all workers have a safe place of work, advice safe system of work and provide
adequate instructions, training and supervision to enable employees to work in safety.

 Carry out site survey on daily basis to ensure that the HSE Methods of working are in
operation & that all regulations are being observed.

 Report, determine & analyze the cause of any accident or dangerous occurrence and
recommend measures for preventing recurrence.

Site Engineer
 Adheres to the Project specific method statements, procedures, inspection programs & HSE
instructions to get the activities performed to CLIENT satisfaction with full coordination with
the HSE & Quality personnel.

 Ensure that all personnel under their control have attended safety induction training, are
adequately inform about foreseeable hazards, preventive or precautionary measures, and
instructed on the system of work to be employed.

Chief Surveyor/Surveyor

 Chief Surveyor: Chief surveyor will be in‐charge of the Topographic survey. He will lead the
survey team and will coordinate with all the concerned parties and ensure survey work is in
time and with proper quality.

 Surveyors: The surveyor will be responsible for all survey work and will report to chief
surveyor.

Foreman/ Work Supervisor

 Responsible for daily activities and resources (labor, machinery, material etc...) are
effectively utilized and monitored in order to achieve HSE & Quality requirements.

Workforce (Labor)
 Carry out their work under direct supervision by their Foreman and charge hand and under
instruction from the Site Engineer to ensure all works are undertaken in a safe manner.
 The workforce to attend a daily Tool Box Talks and morning task briefs prior to starting any new
works.
 The workforce shall receive a full Project briefing and site rules induction prior to commencing any
work on site.

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 Sub-Contractor (BSI Steel)

Chief Executive Officer (CEO)

 Decides or guides courses of action in operations by staff
 Oversees operations of organization
 Implements Plans
 Manages human resources of organization
 Manages financial and physical resources
 Oversees design, marketing, promotion, delivery and quality of programs, products and
services
 Effectively manages the human resources of the organization according to authorized
personnel policies and procedures that fully conform to current laws and regulations.

Project Manager
 Organize the site so that work is carried out to the required specifications with a minimum
risk to men, equipment and materials.
 Adhere to the Project Specific Quality Management Program and HSE Requirements.
Coordination with erection and the Client Representative.
 Delegating tasks to the Construction manager and responsibilities, coordination of the work
planning activities.
 Organizing the team and coordinating with Project/ site engineer.
 Setting the work objectives in view.
 Compliance with H&S requirements as per approved H&S Plan.
 Coordinating with Main Contractor and the Client Representative.
 Delegating tasks to the site engineers and responsibilities, coordination of the work planning
activities.

Operation Manager
 Report to the CEO. Make Production Plans and evaluate Production performance.
 Ensure fabrication activities and achieved within the schedule and compliant with HSE and
Quality requirements.
 Ensure that the plant and workforce are available to meet the requirements of the contract
schedule.
 Manage day to day operational aspects of a project and scope.
 Effectively applies methodology and enforces project standards.
 Coordinating with Main Contractor and the Client Representative.
 Delegating tasks to the site engineers and responsibilities, coordination of the work planning
activities.
 Organizing the team and coordinating with Project / site engineer.
 Setting the work objectives in view.

Production Manager
 Implement and maintain a successful completion of work.
 Ensure that this method of statement is being implemented correctly.
 Ensure that sufficient resources are allocated to enable full compliance with this document.
 Ensure that all works are being carried out as per the project specifications and approved
drawings.

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  Keep all his personnel fully aware of the quality control principles and he shall support to the
project quality control department.
 Responsible for the coordination of Pre‐fabrication, welding, and Painting processes
respectively.
 Coordination and supervision of production foreman and lead man.
 Implement production plans to achieve target production goals.
 Ensure manpower availability and planning based on the production plan.
 Develop fabrication plan that reduce scraps and production delay.
 Distribute workload to respective sections.
 Preparation of labour schedule on weekly and monthly basis and planning its implementation.

Plant Superintendent
 Report to the CEO. Make Production Plans and evaluate Production performance.
 Setting the work objectives in view.
 Implement and maintain a successful completion of work.
 Ensure that this method of statement is being implemented correctly.
 Ensure that sufficient resources are allocated to enable full compliance with this document.
 Ensure that all works are being carried out as per the project specifications and approved
drawings.
 Keep all his personnel fully aware of the quality control principles and he shall support to the
project quality control department.
 Responsible for the coordination of Pre‐fabrication, welding, and Painting processes
respectively.
 Coordination and supervision of production foreman and lead man.
 Implement production plans to achieve target production goals.
 Ensure manpower availability and planning based on the production plan.
 Develop fabrication plan that reduce scraps and production delay.
 Distribute workload to respective sections.
 Preparation of labour schedule on weekly and monthly basis and planning its implementation.

Fabrication Supervisor/General Foreman

 Responsible distributing Shop Drawing to all fabrication Lead man.
 Coordination of the plan for all Lead man assigned in all stage of fabrication processes.
 Assist the QA/QC Personnel to execute and maintain overall quality of the work on daily basis.
 Coordination and supervision of production lead man and workers.
 Implement production plans to achieve target production goals.
 Ensure manpower availability and planning based on the production plan.
 Implement labour schedule on weekly and monthly basis and planning.
 Ensure that the working area is safe for the workers and equipment’s.

Fabrication Foreman / Leadman

 Responsible for checking shop drawing from preparation, fitting assembly, welding processes.
 Responsible to meet product requirement as per production.
 To use manpower efficient and effective.
 Check daily work performance of welder, fitters and operators.
 To raise inspection request to foreman for request for inspection.
 Proposal of repair method in any non‐conformity.

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  Daily preparation of reports, parts, assembly, etc. use of manpower and other necessary
reports.

Welding Foreman / Leadman

 Responsible for checking shop drawing from fit‐up preparation assembly, welding processes.
 Responsible to meet product requirement as per production.
 To use manpower efficient and effective.
 Check daily work performance of welder and operators.
 To raise inspection request to General foreman for request for inspection.
 Proposal of repair method in any non‐conformity.
 Daily preparation of reports, parts, assembly, etc. use of manpower and other necessary
reports.

Welders/Operators
 Welder and welding operator shall be qualified by independent third party agency.
 Wear of proper Personal Protective Equipment (PPE) during welding activity.
 Produce complete and good welding for component as per shop drawing and job
requirements.
 Remove surface spatters by grinding after welding. Grind and clean burrs and sharp edges.
 Visually check welded length for the compliance with requirements.
 Ensure all the safety precautions required for the welding machine, gas cylinder has been
followed during welding activities.
 Ensure cleanliness of the area to be welded, free from rust, oil and other contamination, to
avoid any indication after welding.
 Daily preparation of reports as required by fabrication.

QA/QC Manager
 Responsible by managing the quality of PEB/Structural Steel Fabrication process and assuring
that all quality performed in accordance with company quality system, codes and standards
for customer requirements and satisfaction.
 Responsible for all PEB and Structural QA/QC activities including but no limited to continuous
development of Quality processes, Procedures that support the manufacturing operation.
 Responsible for assuring the qualification of welders, welding processes and procedure.
 Responsible for daily functions and operation of QA/QC Department.
 Interface with the Production and Erection Personnel to identify and troubleshoot materials
and /or workmanship issues.
 Ensures materials and workmanship meet applicable industry codes and standards.
 Plans and Coordinates weekly/daily schedule of Department Supervisor, Engineers and Staff.
 Review/Approved all Quality Plan, ITP, Method Statements and other QA/QC
Procedures/documents as required by the customer.
 Participated Strategic Planning to ensure that all quality requirements are met from start to
finish product.
 Communicates and work with customer’s quality requirements, concerns and issues.

QA/QC Superintendent
 Responsible for Supervising and delegating the task to QA/QC Engineers, Inspectors and staff.
 Ensure that quality work performances are meet for most efficient and effective quality goals.
 Ensures materials and workmanship meet as per applicable industry codes and standards.

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  Interface with the Production and Erection Personnel to identify and troubleshoot materials
and /or workmanship issues.
 Plans and Coordinates weekly/daily schedule of Department Engineers, Inspector and Staff.
 Review all the Quality Reports, NCR’s and implement corrective action plan.

 Prepare all Quality Plan, ITP, Method Statements and other QA/QC Procedures/documents as
required by the customer.
 Participate Strategic Planning to ensure that all quality requirements are met from start to
finish product.
 Communicates and work with customer’s quality requirements, concerns and issues.

Welding Engineer/ Inspector

 Supervise Welding Operation and witness mechanical Testing.
 Carry out daily welding inspection and records.
 Perform visual inspection on welds and request NDT as per requirements.
 Perform weld log and weld map.
 Ensure all welders have correct WPS for the application they are welding.
 Work close with Fabrication department in all quality related matters.
 Analyzed weld repair status and weld performance.
 Supervise welders/operator qualification and training.

Dimensional Inspector
 Ensure materials traceability of the assembled parts or components.
 Perform daily dimensional inspection based on shop drawing, applicable standard and
company tolerances.
 Perform visual inspection to ensure correct alignment of all fit‐up component assembly.

Surface Preparation and Painting Inspector

 Supervise Blasting Operators and Painting applicator for all blasting/painting activities and
training.
 Performs weather conditions checking.
 Performs Surface profile checking, WFT, DFT and painted materials records
 Performs the paint consumable inspection report.

Maintenance Manager
 Responsible to ensure that machinery is in good working condition, capable or producing
parts consisting QC standard.
 Coordination of the plan for all Incharge in Fabrication assigned in all stage of fabrication
processes.
 Coordination and supervision of maintenance personnel, Foreman and staff.
 Implement Daily Preventive maintenance for all Plant Equipments to achieve target goals.
 Ensure manpower availability and planning based on the production plan.
 Implement labour schedule on weekly and monthly basis and planning.
 Ensure that the working area is safe for the workers and equipment’s.

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 Controller/Store Keeper

 Daily issuance of production/maintenance stock such and consumable and spare parts.
 Monitor stock level and create purchase requisition as required for monthly use.
 Issuance of stock for production and spare parts for machine spare parts
 Encoding of daily withdrawal to BSI Maintenance software
 Making purchase request for stock replacement
 Receiving of delivery from suppliers.
 Filling and encoding of delivery notes and submission of invoice to finance.

Crane and equipment operator

 Ensure operators are in possession of and have been briefed on the Permit to Lift and have
signed the relevant section.
 Position the crane as instructed, in accordance with the Permit to Lift.
 Operate in accordance with the Permit to Lift.
 Inform the Lift Supervisor, Signaler/Slinger if any problems arise which would affect the
lifting operation.
 Operate the crane in accordance with the crane’s operating instructions.

Safety Officer
 Promote occupational health and safety within an organization and develop safer and
healthier ways of working.
 Ensure that all activity workplaces and workplace equipment conform to organizational
procedure and safety standards.
 Work with Engineers and other Professionals to ensure the safety of worksites and work
practices.
 Ensure Personal Protective Equipment (such as hearing protection, dust masks, safety
glasses, and foot wear and safety helmets), is being used in workplaces according to
regulations.
 Ensure dangerous materials are correctly stored.
 Identify and test work areas for potential accident and health hazards, such as toxic fumes
and explosive gas‐air mixture, and implement appropriate control measures.
 Record and report hazards, accidents, injuries and health issues within the workplace.
 Assist with investigation of any accidents and unsafe working conditions, study the possible
causes and recommend remedial action.
 Conduct training sessions for management, supervisors and workers on health and safety
practices and legislation.
 Assist with the rehabilitation of workers after accident or injuries and make sure they
experience a satisfactory return to work.
 Coordinate emergency procedure, mine rescues, fire‐fighting and first aid crews.
 Conducting tool box talk about the work to be performing in site.

Third Party (for testing)

 Will be responsible for carrying out the test at plant, recording the readings.
 Will be responsible for analyse test results with experts involvement.
 And preparation of reports for submission.

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 5. RESOURCES

5.1 Manpower

Item Description Number Remarks

1 Plant Superintendent/Manager 1 ‐
2 General Foreman 1 ‐
3 Maintenance Manager/ Technical Officer 1
4 Maintenance Foreman 1
5 Plant Foreman/Lead‐man 8
6 Safety Officer 1
7 QA/QC Superintendent 1
8 QC/QC Engineer/Inspector 8
9 First Aider 1
10 Male Nurse 1
11 Operators As required
12 Drivers As required
13 Fabricator 14
14 Welder 14
15 Applicator 6
16 Blaster 6
17 Helper 6
18 Labour 12

5.2 Plant Equipment

The following equipment’s and materials shall be used for the works:

Item Key equipment No.

1 Air Compressor 2
2 Beam welder station 2
3 Tack weld station 2
4 Seam weld station 2
5 Curve panel machine 2
6 Down spot Bender 2
7 Down spot roll former 1
8 Fire pump Diesel 1
9 Fire Pump electrical 2
10 Flame cutting machine 1
11 Hydraulic press break 2
12 Milling Machine 1

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 Item Key equipment No.
13 Overhead cranes 5 Tons 6
14 Jib Crane 3 Tons 1
15 Radial Drilling Machine 3
16 Rod Treading machine 2
17 Roll forming machine “Z” & “C” 2
18 Shearing Machine 3
19 Sheet folding machine 1
20 Shot blasting machine 1
21 Manual blasting machine 1
22 Steel Decking machine 1
23 Sheet roll forming machine 2
24 Vacuum lifter machine 2
25 Welding machine 30
26 Mother Oven 3
27 Portable oven(quiver) 10
28 Fork Lift 3.0 tons 1
29 Fork lift 5.0 tons 2
30 Side Loader Fork lift 5.0 tons 1
31 Airless Spray Machine 4
32 PPE for Blasting Technicians 1 set/ blaster
1) Hard Hats,
2) Safety Shoes,
3) Safety Goggles,
4) Safety Gloves,
5) Dust Respirators (Dust Masks or Filler
Masks)
6) Ear Protection (Ear Plugs or Ear
mufflers)
7) Face shield for Blasting and Priming and
other PPE, etc.

5.3 Materials

 Cold form Purlins & Grits (GI Coils)

 Anchor Bolt
 Plate
 Rafters
 Columns
 Beams

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  Round bar (Rod bracing, Sag rod)
 Angle bar(Flange bracing, angle brace)
 Connection Bolt (Hex bolt, nut & washer

5.4 Process Involved

 Plates of desired thickness

 Cutting to the required size.
 Assembling
 Welding thru SAW Process & FCAW process
 NDT after final welding
 Surface Preparation and Primer to Topcoat application

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 6. HEALTH/ SAFETY/ ENVIRONMETAL PROTECTION

6.1 Health and Safety

The health and safety activities are to be in accordance with the relevant Health, Safety and
Environmental requirements as described, but not limited to, within the guidelines for method
statement.

Ensure that every one Use the Mandatory and appropriate PPEs for performing the each type
of work.
Minimum Personnel will be permitted in the area while operations are been carried out. At the
start of each work shift for any relevant activity on hand, the “Daily pre start talks” and Safe
working instructions 1‐ 2 times per week will be done on site. Please refer the Approved Health
and Safety plan.

6.1.1 Emergency Response

In case any accident causing injury to personnel, the male nurse will be immediately
notified and he will come to the spot with necessary medicines & equipment’s, to
administer treatment. The Safety Supervisor/Officer or any other supervisor or
foreman, who is certified in first aid, shall give first aid treatment will the arrival of the
nurse. If the injury is of serious nature, the injured person will be transferred to
hospital in ambulance on call.

6.2 Fabrication

6.2.1 Protective & Safety Equipment

All personnel involve in Fabrication works will wear the required PPEs as defined on
FSHM(Fire, safety and Health manual) for fabrication work rules:
8) Hard Hats,
9) Safety Shoes,
10) Safety Goggles,
11) Safety Gloves,
12) Dust Respirators,
13) Ear Protection,
14) Face shield for welding and other welding PPE, etc.

6.2.2 Procedure
The Plant HSE Engineer/Officer is responsible along the key personnel for ensuring that
all operations are carried out with due regards to the safety of all project personnel and
property.
1) Safety
 Tool Box talks to be considered on daily basis
 All workers shall be aware of the activities being carried out and emergency
response plan.
 Critical activities (i.e. heavy lifting) shall only be carried after getting the
approval of its lifting calculation.

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 2) Material storage
 When off‐loading of fabricated steel structure shall be lowered to the ground,
either manually or with mechanically aid like Forklift or crane depending on the
quality, and should not be dropped on the ground.
 Steel fabricated structures shall be stored in the place free of water and secure
area to avoid any kind of damages.
3) Housekeeping
 Shop fabrication area to be maintained clean, tidy and free from hazards.
Housekeeping shall be done on daily basis.
4) Security
 Material, machines and equipment, etc. in the plant will be secured from thefts
and damages.
5) Heavy Lifting Equipment to be use.
 Overhead Crane
 Fork Lift
 Side Loader
6) List if Safety Fire Fighting Equipments/ Emergency Contacts:

BSI Plant Facility – Fire Extinguisher

Location Area Quantity Type

(Unit)
BAY #1 Fab. Area (E‐1, E‐6, E‐10, D‐13, D‐1) 5 Dry Powder
Bay #2 fab. Area (F‐12, F‐3, F‐13, F‐10, F‐9) 5 Dry Powder
Bay #3 Fab. Area (G‐3, G‐6,G‐8, G‐10, F‐11, F‐7, F‐5) 7 ABC & Dry Powder
Bay #4 Blasting & Painting Area (G‐1, G‐5,J‐5, G‐6, J‐3, G‐8, G‐10, J‐11, G‐13,
12 ABC & Dry Powder
Paint Storage area)

Machine Shop 3 ABC, Dry Powder, CO2

Office Ground Floor, Mesh Hall, Toilet, Storage Room 10 ABC, Dry Powder, CO2
First floor Offices, Hallway, stairs 6 ABC Powder

EMERGENCY CONTACTS

Name Contact Number

Ghassan Abdul Wahab (Sale Manager) 3322‐9983
Romeo Santhosh (Plant Superintendent) 5511‐0193
Ghasan Nazih (Plant Foreman) 3349‐6877
Reynalyn Cabreros (HRAD Asst. Manager) 55296358
Mandy Ortega (Maintenance Manager) 5511‐0196
Sam Davis (Nurse/Paramedic) 6611‐8677
Romel Canja (Safety Officer) 6681‐0323
Surya Bahadur Bohora (Security Guard) 7736‐1221
Local Police, Ambulance and Fire 999
Hamad General Hospital (Reception) 4439‐4444
Hamad General Hospital (Emergency‐24 Hrs) 4439‐2111
Qatar Red Crescent: Workers Health Centre (NIA) 5535‐1754

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 7. SEQUENCE OF WORKS

7.1 Area of the works

The Structural steel fabrication work will be carried out for all PEB Buildings of Tamim Air Base
Project with contract No.C‐108‐1 at Dukhan, State of Qatar. The works shall be constructed
by M/s Bahadir Construction.

7.2 Programmed / Timeline of the works

 As per approved recovery Program

7.3 Sequence of works for Fabrication Process

7.3.1 Suitable Raw Materials

 Project Specification ‐ Specification Section 16
 Project Specification – Architectural –Civil‐Structural –Section 16
 Raw materials shall be free from harmful visual defects.
 Raw materials shall confirm to the specification as per fabrication drawing approved by the
Client.

7.3.2 Preparation of Base plate/Flanges/Web/Connection Plates & Others

1. Shearing / cutting and hole punching /drilling – approved materials shall be confirmed to the
required dimension on the shop drawing and cutting list. The used of cutting sketches/plans shall be
used to minimized wastage.

I. Base/End Plates ‐ the actual material shall be taken from mother plate (T = 5‐50mm) x W2000 x L6000
mm size) using CNC Flame (Oxygen fuel gas) Cutting machine (FCM‐302). The CNC Flame cutting
machine shall be programmed or set‐up from the required width or length depends on effective sizes
that shall be divided from one mother plate.
MEL No: FCM‐302

SERIAL No: 14051040

CAPACITY:

Thickness 5~50mm
Length 6000mm
Nozzle head (straight cut) 11
Nozzle head (automatic cut) 2

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 Example of Cutting of Base Plates/Heavy Thickness Connection Plates

II. Flanges/Web – the actual materials shall be taken from mother plate (T =6‐12mm) x W200 x L6000 mm
size). Mother plate with full length 6 meters or 2 meters width will be divided during actual dimensional
layout before the actual cutting. The two (2) big shearing machines (SMI‐306 & SMQ‐308) shall be used.
III. Connection Plates/stiffeners/small clips – these shall be cut by small shearing machine (SMQ‐307). The
same type of materials shall be used from mother plates or plate excess materials from big shearing
machines.

Shear Machine limits Shear(SMI‐306) Shear‐small (SMQ‐307) Shear‐Big (SMQ‐308)

Thickness 1.5 ~12mm 1.5 ~16mm 1.5 ~30mm

Length 6000mm 3200mm 6000mm

MEL No: SMI‐306 MEL No: SMQ‐307 MEL No: SMQ‐308

SERIAL No:0602228 SERIAL No:573 SERIAL No: Q2893

Ex. Of Sheared web components (ready Ex. Of Sheared small components (ready for Ex. Of Sheared flange components (ready
for web to flange joints) drilling and others for flange to web joints)

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 IV. Marking and Traceability – The material identification from shop drawing such as job number, piece
mark, dimensions shall be transferred from all cut pieces during layout stage or before leaving at the
cutting bench. The materials heat numbers shall exist on the cut materials and heat number shall be
clearly transferred to cut pieces before leaving them to cutting bench by either hard stamp or paint
marker. Prior/after to any cutting operation, the heat number shall be transferred to web, flange and
base plates in order to maintain traceability.
V. Hole Drilling and Punching – after cutting/shearing of base/end plates, connection plates or clips, all
those material shall be transferred for hole punching (GEKA Universal Iron Worker Machine ‐ for clip,
stiffeners or small hole diameter) and drilling machine (Radial Drilling Machine) respectively. First, the
operator will make the dimensional layout and hard punch for identifying the location of the hole. It will
serve as a pattern for all plates with the same dimension (hole diameter, gauge, length, width and
thickness) as per shop drawing and specification.
Punching – Universal Iron worker Machine Limit (GIW‐206 & 208)

Thickness 3~20mm
Width 50~500
Available Hole Diameter Available Slotted Holes Diameter
8 mm 15 x 20 mm
12 mm 15 x 21 mm
14 mm 15 x 30 mm
16 mm 15 x 35 mm
18 mm 15 x 40 mm
22 mm 18 x 40 mm
24 mm 24 x 26 mm

Example below photograph of sheared & drilled material

MEL No: GIW‐206, 208
components (stiffeners, clips, loose clip, etc. can be done in
SERIAL No:20746 , 22300
GEKA machine.
QUANTITY: 2 UNIT(GEKA)

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 Drilling Machine – Radial Drilling Machine Limit (RDM 206 to 210)

Thickness 15 ~ 120mm Combined

Available Hole Diameter 12 ~ 50mm

MEL No: RDM‐206 ~ 210

MEL No: UIW‐201
SERIAL No: NR 78002, 0805003, 201405182, 201405181, 201405183
SERIAL No: DIW‐160L

Ex. Of Base Plate, End Plate (After hole drilling – Heavy thickness) Ex. of Stiffeners, clips, gusset (After hole punching/notching)

VI. Flanges to Flange Joint ‐ the flanges cut at the shearing shall be transferred to Flange line for
Butt weld Joint (FBW‐301). Flange Joint (for more than 6 meters of beam) shall be joint using
Flux Core Ark Welding Machine (FCAW) process as according AWS D1.1 and attached WPS
No.FCAW‐02 for butt weld joint. After the joint, it will ready materials for web to flange
assembly joint in beam line process as per approved shop drawing.

Flange line(FBW‐301) (Flange to Flange Joint) Flange line(FBW‐301) (Flange to Flange Joint)

Conveyor system to put the sheared plate materials for Butt weld joint (CJP) using FCAW process.
flanges

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 2. Grinding – material surface and edge shall be smooth, uniform and free from burrs tears and other
defect which would affect the quality and strength of weld. Surfaces adjacent to weld shall be free
from loose, thick scale, slag, rust, moisture, grease or other foreign material that would prevent
proper welding. Roughness of oxygen surfaces and oxide deposited shall be removed by machining
or grinding. Cut surfaces and edges shall be ground smooth.

3. Welding procedure (attached WPS) to be use and proposed shall be submitted for third party
inspection Agency (TPI) and or Customer for review / approval.

4. Qualification of welders / welding operator shall be qualified via qualification testing as per the
requirement applicable code and standard and customer requirements.

7.3.3 Visual Inspection and Repair with Edge Flame Cut Edge
1. The preparation of base metal and acceptance criteria of discontinuities and the repair method will
be accordance with the applicable clauses of section 5.15 of AWS D1.1/D1.1M:2010.
2. All Flame cut edges shall be to clean and visually inspected to ensure no laminations crack, flutes,
etc. Any defects shall be removed by minimum depth of 5mm. If the defects still exist it shall
further be excavated and repaired using a related WPS.

7.3.4 Fitting (Assembly & Web to Flange Joint)

1. The structural Beam Fabrication Line produced straight and tapered “T” and “I” section steel
structural beams. The Structural Beam Fabrication Line (can see at AutoCAD drawing 121036‐002
“Operation and Maintenance Manual” of BEAM LINE) consists of SEAM Welder Station (SWS‐201),
Tack Fixture Station (TWS‐202), Main Welder Station (BWS‐203) and the Conveyor System. The
operator or each station controls the machine (Seam Welder, Tack Fixture or Main Welder) and
Conveyor section, associated with it.
I. The Seam Welder joints adjacent web section together with a 100% welded seam. Process
reference as according to the attached WPS No. SAW‐02 and WPS No. SAW‐03 (Submerge Arc
Welding Process).
II. The Tack Welder positions and clamps the web and two flanges together in proper relationship
to allow the operator to tack weld the leading edge of the beam. Process reference as
according to the attached WPS No. SMAW‐01 (Shielded Metal Arc welding Process).
III. The Main Welder position, guides and drives the tack‐welded beam through, while
simultaneously weld two flanges to the web with one pass of Two Submerged Arcs, from the
same side of the web. Process Reference as according to the attached WPS No. SAW‐01
(Submerge Arc Welding Process).
IV. Conveyor System moves web, flanges, and tack‐welded beams to and from respective stations.

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 Automatic Beam Welder Machine Limits – BWS‐203, TWS‐202, SWS‐201

Web Thickness 3 ~ 16mm

Web Height 130 ~ 1800
Web Taper max.deg. 15 deg. Max
Flange Thickness 5 ~ 38mm
Flange Width 100 ~ 500
Min.Beam Length 2000mm
Max.Beam Length 15000mm
Beam Weight Max.Kg/M 518 Kg/Meter
Weld Fillet Size 3 ~ 8mm
Welding Speed m/min. 0.5 ~ 3.0

MEL No: SWS‐201 MEL No: TWS‐102 MEL No: BWS‐203

SERIAL No:004‐03‐08 SERIAL No: N/A SERIAL No:002‐3‐08

Ex. Of Web to web joint Ex. Of Web to flange(Temporary weld) Ex. Of Web to Flange Joint (SAW process)

2. The parts to be joined by fillet welds shall be brought as close a particle. The root opening or gap
shall be as per welding procedure.
3. Member to be weld shall be brought into correct alignment and held in position by bolt, clamps,
wedges struts, and other suitable devices or by tack welds until welding has been completed. The
jigs and fixtures are recommended where practicable. Restrict the amount attachments welded to
permanent materials.

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 7.3.5 Fitting Assembly (Component Tack Welding)
1. All materials that has been finished at Beam Line station (flange and web automatic welded joint)
shall proceed with the final fit‐up assembly. Fit‐up assembly reference as according to the
attached WPS No. SMAW‐01 (Shielded Metal Arc Welding Process).
2. The fitter assigned in every fitting bench is responsible to do the proper fit‐up assembly of all
connected components required for each beam as per details and shop drawing. Material to be
joint by tack welding such as base/end plates, stiffeners, gusset clips, girt or purlin clips, etc. shall
be smoothly grind or prepared as detailed in the shop drawing.
3. Tack welds shall be subjected to the same requirement as final welds.

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 4. Track welds which are constituting part of the final weld shall make with electrodes meeting the
requirements of the final weld electrodes meeting the requirements of the final weld and shall be
cleaned thoroughly. Multiple pass tack welds shall have cascaded ends.
5. Tack welds not consulting part of the final weld shall be removed by grinding. Surface shall be good
to the original one and make sure that the area is defect free.
6. Tack welds to form part of the welds are not permitted in end or corner area.
7. Tack welding shall be performed by using the same approved welding procedure for the production
welding.
8. After completing the assembly, dimensional control shall be performed in accordance with AWS
D1.1 requirements or shop drawings.
9. All assembly numbers such us Job# ‐ Building # (Facility#) ‐ Part # ‐ Individual Qty if more than 1
piece (ex. QA‐667‐02(508)‐PH2‐ C34#2) shall be clearly marked by hard stamp punching. Hard stamp
punch height shall be min. 12 mm.
10. Hard punch should be located at specific/visible location. Not on base plate or top plate of column,
all items mark should be on specified location. It will be located at the top flange column, rafter and
will start at least 100 mm from base line.
11. Special inspection to be conducted by Plant QC for heat distortion at the connection plates to avoid
issue on site. Fabricators to put enough temporary bracing/support if necessary to avoid more
distortion after final welding.
12. Dimensional tolerances shall be in compliance with Project Specifications & QCS 2014.

Materials from Beam‐line (web to flage) Start fit‐up assembly preparation (cutting, Base‐plate/End plate connections layout
grinding, etc.)

Fit‐up of other connection, stiffeners, Ex. Hard stamp marking (Job#, Building#, QC Final Fit‐up Dimensional Inspection
purlin/girt clip, gusset clip, others Facility#, Phase#, Part#, Qty. located at top
flange of column, rafter and will start of least
100 mm from base line

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 7.3.6 Final Welding (Repair / Correction)
1. The removal of weld metal or portions of the base metal may be done by machining, chipping or
gouging and in a manner that the adjacent weld metal or brass metal is not nicked or gouged.
Defective portion of weld shall be removed without substantial removal of the base metal. Conduct
visual and or appropriate NDE (If applicable).
2. The Surfaces are to be cleaned thoroughly before welding.
3. Defective or unsound weld or base metal shall be corrected either by repairing or replacing the
entire weld.
4. Overlap or excessive convexity is to be reduced by removal of excess metal.
5. Excess concavity of weld or crater, under sized welds and under cutting shall be dressed and
deposited with additional weld metal.
6. Excessive weld porosity, excessive slag inclusions and incomplete fusion shall be suitably removed
and re welded.
7. In cracks of the weld or base metal, ascertain the extent of crack or cracks by suitable NDE method
(if applicable ) or other regular means and remove the crack and sound metal 50mm beyond each
end of the crack. Conduct visual prior to re‐welding.
8. Members distorted by welding shall be straightened by applying a limited amount of localized
heating with the temperature of the heated areas no exceeding 315degree Celsius, as measured
through approved methods. The parts to be heated for straightening shall be substantially free from
stress or from external forces as according to Art. 5.26.2 of AWS D1.1. Heat straightening or curving
of distorted members is permitted by the existing AWS specification. Fabricated members shall be
corrected based on the following:
9. The use on controlled heat straightening, curving or cambering, in accordance with AWS D1.1 should
be allowed.
10. Since the maximum temperature permitted by AWS D1.1 is below the lower critical temperature for
the materials being heated, the temperature shall be down of at least 150`C before applying the
accelerated cooling water thereof will not be detrimental to the physical properties of the material
and will not affect structural integrity.
11. Heating Equipment shall be performed using heating torches and using (i.e. acetylene / oxygen or
natural gas)
12. Heating shall be confined to the pattern described herein and shall be conducted to bring the steel
within the planned pattern to temperature not exceeding 315`C.
13. Heating patterns shall be spaced uniformity along the full length of each flange or it shall be adjusted
to produce the necessary shape, straightness or flatness of the component.
14. For sweep components, heating pattern shall be marked on the flange prior to heating. Heat shall be
on applied to the top and bottom flange at essentially the same location in the member.
15. Heat shall not be applied to the inside flange surface until the heat being applied outside surface has
progressed beyond the web and flange junction.
16. The Inspector shall conduct temperature test indicating crayons manufactured for 600`F (315`C)
1.000`F (590`C). Heat measurement shall be made after heating flame has been removed from the
steel. Wait until the temperature down to at least 150`c, then accelerated cooling water shall be
applied on the heated area of the flange.
17. Visual inspection shall be carried out for the straightness or flatness of the materials after the
process.
18. Acceptance Criteria for Weld Visual Inspection shall be detailed in accordance with relevant clauses
of AWS D 1.1 & Project Specification requirements.

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 19. All the weld joints internal or external, CJP (Complete Joint Penetration), PJP (Partial Joint
Penetration) & Fillets Welds to be cleaned properly for weld slag & all the weld visual repair
encountered to be addressed and completed in accordance with AWS D 1.1 & Project Specifications

20. All weld shall be visually inspected and shall be acceptable if the criteria of table 6.1 are satisfied.
See Table 6.1 of AWS D1.1.
21. Visual Inspection of weld according to QCS 2014 Section 16 “Structural Steelworks” Part 5 “Welding”
to 5.5.2 Visual inspection of Welds. (1)Visual inspection shall be made in accordance with the
guidance in BS 5289 over the full length of the weld before NDT inspection is performed.

Welded PEB materials after final welding process Visual and dimensional inspection of weld

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 7.3.7 Non-Dectructive Testing (NDT)
1. NDE Shall be conducted on the weld joints in accordance to the Specifications/QCS 2014 by
Approved Third Party Agency.

Magnetic Particle Test (MPT) for the Butt weld joint Magnetic Particle Test(MPT) for Fillet weld
for 10mm and below. joints,Partial Joints penetration

Ultrasonic Test – for Butt weld joint (CJP)

2. Visual Inspection Acceptance Criteria(AWS D1.1 table 6.1) and Visual Inspection of weld according
to QCS 2014 Section 16 “Structural Steelworks” Part 5 “Welding” to 5.5.2 Visual inspection of Welds.
(1) Visual inspection shall be made in accordance with the guidance in BS 5289 over the full length of
the weld before NDT inspection is performed (Reference Table 5.2) or as per approved ITP.
3. Acceptance Criteria & Frequency of Inspection (NDE) to be detailed in compliance with AWS D 1.1 &
Project Specifications and approved ITP. (Reference QCS 2014 Sec 16 Part 5 for the “weld Quality
Acceptance Criteria and Corrective Action”.

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 7.4 Environmental Issues
The activities for environmental preservation through mitigation will be in accordance with the
CEMP. Environmental Risk Assessment, as presented as appendix to this MS, for the structural
steel fabrication as well as the approved CEMP serves as the basis of the proposed
environmental management plan for the structural steel fabrication.

Environmental aspects during the structural steel fabrication are as follows:

a. Air Emissions and Dust Generation
b. Noise
c. Waste generation
d. Spillage
Specific management plan have been detailed in the MOE approved Construction Environment
Management Plan (CEMP) for above referred Environmental Aspects.
However, to ensure the environmental management requirements are considered and controls
implemented such as at the present case the following specific Environmental Management Plan
(EMP) will be implemented:

7.4.1 Impacts
The possible impacts are as follows,

a. Air Emissions and Dust Generation – Pollute the atmospheric air

b. Noise – major hearing problems to the workers
c. Water – contaminates ground water
d. Solid Waste generation – contaminates the soil and natural ground.
e. Prime Storage/ Spill – contaminates the ground if placed without ground
protection, explosion in case of fire in the work area.

7.4.2 Mitigation Measures

The mitigation measures are to specifically address the identified environmental
impacts, in addition to and not limited to, the items as described within the guidelines
for method statement.

EMP for Air Emissions & Dust Generation:

1. Minimize vehicular movements and implement speed control
2. Periodic water sprinkling for dust suppression at and around work area to
minimize airborne dust.

EMP for Noise:

1. Ensure field equipment maintenance team undertakes schedule preventive

maintenance and replacement of worn out components to minimize noise
pollution.

EMP for Water:

1. Provision of appropriate secondary containment at work site to prevent ground

water contamination.

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 2. Ensure the preventative maintenance at storage of Primes.

EMP for Solid Waste generation:

1. Tool box talk and implementation of 3R at waste management practices: (Reduce,

Recycle and Reuse)
2. Ensure segregation of waste and provide adequate waste skips for Non‐Hazardous
wastes (degradable wastes/plastics/paper & cardboard/metal) and Hazardous
Wastes (contaminated soil/oil‐soaked waste cotton & gloves/oil filters/etc.,)

EMP for Prime Storage /Spill:

1. Ensure that all Primes to be used are lead free and are not listed to be scrutinized
under the Rotterdam Convention (PIC: Prior Informed Consent)
2. Primes (including primers, coating agents) should not be stored other than
designated area within the project site. Empty Prime containers should be
disposed appropriately in line with their respective MSDS.
3. Appropriate Secondary containment to be provided at work site to prevent soil
pollution in event of spillage.
4. Tool box talk and implementation of Project Spill Prevention and Control Plan.

8. Appendix: ENVIRONMENTAL RISK ASSESSMENT

The process of evaluating the significance levels of environmental impacts from construction activities
and the sensitivity of the environmental component is referred to as the environmental risk
assessment. The process of environmental risk evaluation shall, where relevant, consider the
following activities during structural steel fabrication:

 Emission to air.
 Waste management.
 Contamination of land.
 Applicable legal and other requirements.
 Different operations conditions (e.g. day to day, abnormal, emergency situations).
The method of carrying out the Environmental risk evaluation has been based and influenced by the
following considerations compiled for:

 Impact Severity;
 Impact Duration and
 Probability of Occurrence
The matrix is based on the formula:

Environmental Risk (R) = Severity (S) x Duration (D) x Probability (P)

These considerations are elaborated as how the ERA is conducted at the matrix in the following
Tables C‐1 to Table C‐3. A risk rating of each aspect has been derived based on impacts of Severity,
duration and probability and expressed as Critical, Significant, Moderate, Low or none as reflected at

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 These considerations are elaborated as how the ERA is conducted at the matrix in the following
Tables C‐1 to Table C‐3. A risk rating of each aspect has been derived based on impacts of Severity,
duration and probability and expressed as Critical, Significant, Moderate, Low or none as reflected at
Table C‐4. These findings for the activities foreseen to occur during construction & operation phases
of Dewatering facilities have been worked out and presented in Tables C‐5.

Table C‐1: Impact Severity Rating (S) as basis for evaluation

Rating Type Description

No known effect to Natural Habitat, Flora, Fauna, Natural Resources, Land,

1 None
Water & Air

Has Low or negligible effect to Natural Habitat, Flora, Fauna, Natural Resources,
2 Low
Land, Water & Air

May be harmful to Natural Habitat, Flora, Fauna, Natural Resources, Land,

3 Medium
Water & Air

Can cause illness to Fauna and damage to Flora, Natural Resources, Natural
4 Significant
Habitat/Inhabitants, Water, Land & Air

Can cause death to fauna & destruction to Flora, Natural Resources, Natural
5 Very High
Habitats/Inhabitants, Water, Air & Land

Table C‐2: Time Duration (+) of Impact Rating (D) as basis for evaluation

Rating Type Description

Will not occur during any period of time during the activity considered is
1 None
in progress

Will rarely occur and for very short duration only, during the activity
2 Low
considered in progress

Will occur for short durations during the activity considered is under
3 Medium
progress

Will occur for extended durations during the activity considered is under
4 Significant
progress

Will occur more continuous during the activity considered is under

5 Very High
progress

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 Table C‐3: Probability of Occurrence (P) as basis for evaluation

Rating Type Description

1 None The event may not occur normally

2 Low The event could occur at exceptional circumstances

3 Medium The event could occur at some time (once in a while)

4 Significant The event probably will occur in most circumstances

5 Very High The event is expected to occur in most circumstances

Table C‐4: Environmental Risk Rating (S x D x P) employed at evaluation

Score Rating

1‐25 None

26‐50 Low

51‐75 Moderate

76‐100 Significant

101‐125 High Significant (Critical)

In the event any of the aspect is influenced by statutory requirement, the final rating has been considered Significant
and mitigation requirements brought out immaterial of the evaluation process.

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 9. APPENDIX

APPENDIX NO. APPENDIX TITLE REFERENCE

9.1 RISK ASSESSMENT(RA) See Attached

9.2 BSI Steel Fabrication Flow Chart See Attached

Welding Procedure Specification (WPS)/ Procedure

See Below
Qualification Record (PQR)

WPS BSI‐FCAW‐01 &

1. WPS/PQR – Flux Core Arc Welding Process 02
(Qualified)
PQR BSI‐FCAW‐01 & 02

9.3 WPS BSI‐FCAW‐004 &

2. WPS/PQR – Flux Core Arc Welding Process 005
(Qualified) PQR BSI‐FCAW‐004 &
005

3. WPS/PQR – Submerged Arc Welding Process WPS BSI‐SAW‐004

(Qualified) PQR BSI‐SAW‐004

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APPENDIX – 9.1

Risk Assessment
Client: DUKHAN AIR BASE PROJECT Contractor:
Contract No. C-108-1

RISK ASSESSMENT
METHOD STATEMENT FOR STEEL STRUCTURE
FABRICATION FOR BLDG 6656 – AIRCRAFT SHADES

DATE: 20.04.2019 LOCATION: DUKHAN AIR BASE PROJECT ACTIVITY: STEEL STRUCTURE FABRICATION FOR BLDG 6656 – AIRCRAFT SHADES
R=RISK RATING =A x B
S= SEVERITY L = LIKELIHOOD OF OCCURRENCE
1. Severe & Fatality ‐ Multiple LTI or Fatality Certain or Imminent ‐ Absence of control measures to
5= 2. Total structural or environmental damages or 5= prevent occupational hazard to workers, resulting
PMV/Material permanent disability or fatality.
Very Likely ‐ Control measures are not effectively
1. Major – Lost Time Injury (LTI) 2) Operational damages ‐
4= 4= implemented; thus, likelihood of hazard occurrence is high, 01 to 04 LOW
PMV/Material
resulting to Lost Time Injury.
1. Restricted ‐ Restricted Work Case (RWC) injuries Likely ‐ Control measures are in place but the likelihood of
3= 3=
2. Serious damages to PMV/Material/Structure hazard occurrence is minimal, and that the injury is minor 05 to 09 MEDIUM
1. Minor ‐ Medical Treatment Case (MTC) injuries May Happen ‐ Control measures are in place, but the
2= 2. Damage repair need from third party for 2= possibility of hazard may occur due to third party or unsafe
PMV/Material/Structure act or conditions. 10 to 16 HIGH
1. Negligible ‐ First Aid Case (FAC)/Minor damages Very Unlikely ‐ Control measures are effectively
1= 2. Damages is minor and can be repaired internal company 1= implemented, but the resulting injury or illness only requires 17 to 25 SERIOUS
source first aid.

Title: Risk Assessment for MS for Steel Structure Fabrication for Bldg 6656 – Aircraft Shades Page(s):1 of 40
Document No.: TAB-BAH-6656-MS-SE-00053 Rev. 00 Date: 20/04/2019
Client: DUKHAN AIR BASE PROJECT Contractor:
Contract No. C-108-1

RISK ASSESSMENT
METHOD STATEMENT FOR STEEL STRUCTURE
FABRICATION FOR BLDG 6656 – AIRCRAFT SHADES

Prepared by: Mario Marquez Reviewed by: Stuart Tannahill

Date: 20/04/19 Date of Review Pages: 40
Title: QA/QC Superintendent Title: HSE Manager
Location: TAB Project Work Operation: Risk Assessment for Method Statement for Const. & Installation of Pre‐cast wall in all Buildings

Initial Risk Initial Risk

Serial Risk
Rating Rating
Numb Activity # Hazard Probability
RR Controls Probabilit RRF Risk Priority Accept
er yx
x Severity √ or X
Severity
1. Pre-start talk to be carried out to all work force
involved.
2. STARRT talk to be carried out by concerned
engineers.
3. TBT prior to work commencing.
 Workers will get 4. Make sure all new employees undergone induction
Communication of confused, stressed training.
information and  Mistakes may lead to
1 5. Ensure trained, authorized and competent supervision
instructions to work accidents 3 3 9 3 1 3 Low Y
will be in place to monitor workers at all times.
force
6. As a minimum the following information's to be
communicated to workforce, permit required works,
emergency arrangements and contacts.
Welfare and first aid arrangements, Restricted / permit
required areas and Appointed persons

Title: Risk Assessment for MS for Steel Structure Fabrication for Bldg 6656 – Aircraft Shades Page(s):2 of 40
Document No.: TAB-BAH-6656-MS-SE-00053 Rev. 00 Date: 20/04/2019
Client: DUKHAN AIR BASE PROJECT Contractor:
Contract No. C-108-1

RISK ASSESSMENT
METHOD STATEMENT FOR STEEL STRUCTURE
FABRICATION FOR BLDG 6656 – AIRCRAFT SHADES

1. Make sure that all new people must be inducted for

awareness of site safety rules and access and
egress.
2. Pre-start talk
Slip, trip and fall 3. STARRT talk
2 Access & Egress 4 4 16 3 1 3 Low Y
4. Provision of safe access & egress at workplace.
5. Ensure Workplace is free from obstruction.
6. Access way safe and correctly fixed.
7. Access way clearly visible and sign posted.

1. Make sure that all new people must be inducted, for

aware of work shop safety rules and access and
egress
2. STARRT Talk
 Slip, trip and fall
3. Provision of safe access & egress at workplace.
 Incident due to unsafe 4. Ensure Workplace is free from obstructions.
access 5. Access way safe and correctly fixed.
 Electrical hazards 6. Access way clearly visible and sign posted.
 Operating CNC flame 7. All power tools and electrical cables must be
cutting inspected and color coded by competent person
 Machine. (People get 8. Proper housekeeping to be conducted. The
Preparation of Base contact with rotating fabrication area shall be cleared of unwanted
plate/flanges/web/Con part of machine)
3 5 5 25 materials. Barricade or cover the gaps on the floor. 3 1 3 Low Y
nection plate and  Operating shearing 9. Only authorized, trained, certified operators shall
others Machines. (It might operate the machines
be possible hit by 10. CNC machine gas supply hoses shall have in good
flying particles during condition
operation) 11. Flash back arrester shall be available at CNC
 Usage of Drill & punch machine
Machine 12. PTW for hot works shall be obtained.
13. All machines must be tested and tagged by a
qualified, authorized competent person.
14. Cracked handles, damaged cutting edges,
incorrectly secured power supply leads or hoses
shall be checked before use

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Document No.: TAB-BAH-6656-MS-SE-00053 Rev. 00 Date: 20/04/2019
Client: DUKHAN AIR BASE PROJECT Contractor:
Contract No. C-108-1

RISK ASSESSMENT
METHOD STATEMENT FOR STEEL STRUCTURE
FABRICATION FOR BLDG 6656 – AIRCRAFT SHADES

15. Wear correct PPE

1. Pre-start talk,
2. STARRT Talk
3. Reduce source of noise where '•possible, keep
machine covers closed, and turn off machinery when
not in use.
4. Provide warning signs & hearing protection such as
 Slip, trips and fall due to ear muffs in case noise levels are more then 85dBs
wire 5. Carry out Noise monitoring regularly.
 Health hazard 6. Inform other workers in area of any noise hazard.
 Noise 7. Conduct TBT/training for noise hazards
 Hit by flying particles 8. Noise generation equipment shall be inspected prior
during operation to use by trained, authorized and competent person.
 Fire use of earplug, earmuff etc.
 Burns 9. Regular breaks and hourly job rotation to ensure
 Electrical shock and exposure to Noise is limited.
Grinding for material electrocution 10. People get contact with rotating part of power tools.
4 5 5 25 3 2 6 Medium Y
surface  Eye injuries from 11. Provision of firefighting equipment.
dust, swarf or other 12. All electrical cable should be routed in safe manner.
fragments such as keeping at proper level.
 Wrist and hand injuries 13. Minimize personnel in work area.
due to tool jamming or 14. Follow cable management to avoid slips and trips
binding hazards.
 Hand/Arm Vibration 15. Conduct daily housekeeping on the floor. Remove all
Syndrome (HAVS) the flammable materials such as wood, paper, nylon,
 Fire / Explosion etc.
16. Remove combustible materials from the places
where flying sparks create ignition.
17. Wear correct PPE, protect eyes & hands, dust
mask.etc.
18. Vibration resistant hand gloves shall used.
19. All activities should be carried out under trained,
competent supervisors.

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Document No.: TAB-BAH-6656-MS-SE-00053 Rev. 00 Date: 20/04/2019
Client: DUKHAN AIR BASE PROJECT Contractor:
Contract No. C-108-1

RISK ASSESSMENT
METHOD STATEMENT FOR STEEL STRUCTURE
FABRICATION FOR BLDG 6656 – AIRCRAFT SHADES

20. 'Trained, Competent and Authorized operatives are

allowed to use power tools.
21. Qualified, Competent and Authorized electricians to
test all portable electrical equipment at recommended
regular intervals.
22. Employee conducts daily inspections of power tools
(Including electrical cords) before operation and
where faults are identified that require immediate
maintenance the tool is put out of service until
maintenance is conducted by a Trained, Competent
and Authorized person.
23. All power feeds, electrical, pneumatic or hydraulic, to
comply with Qatar National Standards and maintained
in good condition.
24. Ensure that the power tool has the correct guard,
shield or other attachment that the manufacturer
recommends. Ensure all electrical distribution boards
are fitted with ELCB and this is regularly tested to
evaluate if it is working safely or not with immediate
rectification of faults. Relevant Permit to work should
be obtained prior to the start of work.
25. Tools must be used accordance with manufactures
instruction. Select power tools with lowest vibration
level. A tool producing high levels of vibration to have
anti-vibration handles to reduce the risks.
26. Minimize the time individuals use the equipment, i.e
Job rotation.
27. Noise assessment required where deemed
necessary.
28. A safe working platform is required when using a
power tool.
29. Power tools shall only be used in well-lit and
ventilated area.
30. Wear or use personal protective equipment (PPE) or
clothing that is appropriate for the work you are doing

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Document No.: TAB-BAH-6656-MS-SE-00053 Rev. 00 Date: 20/04/2019
Client: DUKHAN AIR BASE PROJECT Contractor:
Contract No. C-108-1

RISK ASSESSMENT
METHOD STATEMENT FOR STEEL STRUCTURE
FABRICATION FOR BLDG 6656 – AIRCRAFT SHADES

this may include, items such as safety glasses or

goggles or face shield (with glasses or goggles),
hearing protection, dust mask, gloves, safety boots or
shoes or rubber boots.
31. Switch off the tools before connecting them to a
power supply.
32. If the power cord feels more than comfortably warm or
if a tool is sparking, have it checked by an electrician
or other qualified person.
33. Disconnect the power supply before making
adjustments or changing accessories.
34. Remove any wrenches and adjusting tools before
turning on a tool.
35. Inspect the cord for fraying or damage before each
use. Tag defective tools must be immediately
returned to the store man.
36. During use, keep power cords clear of tools and the
path that the tool will take.
37. Use clamps, a vice or other devices to hold and
support the piece being worked on, when practical to
do so. This will allow you to use both hands for better
control of the tool and will help prevent injuries if a
tool jams or binds in a work piece.
38. Use only approved extension cords that have the
proper wire size (gauge) for the length of cord and
power requirements of the electric tool that you are
using. This will prevent the cord from overheating.
39. Suspend power cords over aisles or work areas to
eliminate stumbling or tripping hazards.
40. Suspend power cords over aisles or work areas to
eliminate stumbling or tripping hazards.
41. Eliminate octopus connections: if more than one
receptacle plug is needed, use a power bar or power
distribution strip that has an integral power cord and a
built-in over current protection.

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Document No.: TAB-BAH-6656-MS-SE-00053 Rev. 00 Date: 20/04/2019
Client: DUKHAN AIR BASE PROJECT Contractor:
Contract No. C-108-1

RISK ASSESSMENT
METHOD STATEMENT FOR STEEL STRUCTURE
FABRICATION FOR BLDG 6656 – AIRCRAFT SHADES

42. Pull the plug, not the cord when unplugging a tool.
Pulling the cord causes wear and may adversely
affect the wiring to the plug and cause electrical shock
to the operator.
43. Follow good housekeeping procedures - keep the
work area free of clutter and debris that could be
tripping or slipping hazards.
44. Keep power cords away from heat, water, oil, sharp
edges and moving parts. They can damage the
insulation and cause a shock.
45. Ensure that cutting tools, drill bits, etc. are kept sharp,
clean and well maintained.
46. Store tools in a dry, secure location when they are not
being used.
47. Do not wear gloves, loose clothing or jewelry while
using revolving power tools. Tie back long hair or
wear appropriate hair protection to prevent hair from
getting caught in moving parts of equipment.
48. Do not leave a running tool unattended. Do not leave
it until it has been turned off, has stopped running
completely, and has been unplugged
49. Do not expose electric power tools to rain or wet
conditions; wet tools increase the likelihood of electric
shock.
50. Stop using an electric power tool if you feel a tingle in
your fingers. This is a warning that the tool is faulty
and needs repair.
51. Prevent shocks. Ensure that the tools are properly
grounded using an industrial type three-prong plug,
are double-insulated (and are labeled as such), or
are powered by a low-voltage isolation transformer:
this will protect users from an electrical shock, i.e.
110 voltage.
52. Do not walk on or allow vehicles or other moving
equipment to pass over unprotected power cords.

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Document No.: TAB-BAH-6656-MS-SE-00053 Rev. 00 Date: 20/04/2019
Client: DUKHAN AIR BASE PROJECT Contractor:
Contract No. C-108-1

RISK ASSESSMENT
METHOD STATEMENT FOR STEEL STRUCTURE
FABRICATION FOR BLDG 6656 – AIRCRAFT SHADES

Cords should be put in conduits or protected by

placing planks on each side of them.
53. Do not operate tools in an area containing explosive
vapours or gases.
54. Do not clean tools with flammable or toxic solvents.
55. Do not surprise or touch anyone who is operating a
tool. Startling a tool operator could end up causing
an accident or injury.
56. Leather gloves and aprons to be used.

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Document No.: TAB-BAH-6656-MS-SE-00053 Rev. 00 Date: 20/04/2019
Client: DUKHAN AIR BASE PROJECT Contractor:
Contract No. C-108-1

RISK ASSESSMENT
METHOD STATEMENT FOR STEEL STRUCTURE
FABRICATION FOR BLDG 6656 – AIRCRAFT SHADES

1. Pre- start talk/STARRT Talk

2. Special consideration will be given to any hot works
3. Smoking, naked lights and any nylon material should
be prohibited at welding area
4. Equipment which may release excess oxygen or
engines which omit carbon monoxide gas should not
be used at near to confined spaces entrance.
5. Provision of firefighting equipment.
6. Emergency access clearly marked and free from
obstruction.
7. All electrical cable should be routed in safe manner.
such as keeping at height level.
8. Only qualified, authorized and competent person for
the job.
 Fire and explosion 9. Equipment will be in good order & regularly
 Toxic fumes & gases maintained
 Light and heat radiation 10. Ensure that certified, authorized and competent
Welding works (Hot
5  Foreign bodies in the 5 5 25 Welder to inspect equipment daily before use. 3 2 8 Medium Y
Work)
eye 11. Combustible materials should be removed from area
Electrical shock and before work commences.
electrocution 12. Only certified, authorized and competent persons to
operate fusion welding equipment.
13. Minimize personnel in work area.
14. Wear appropriate PPE, hand gloves, safety glass,
safety boots, coverall, apron and Respiratory and air
protection.
15. Maintain good housekeeping.
16. Keep inspected good working condition fire
extinguisher on place.
17. Provision of hot work permit to work system.
18. First aid box kept on working site and assign a trained
authorized and competent first aider.
Qualified, authorized and competent supervision will
be in work Place to monitor work at all time
19. Faulty equipments should be marked clearly and put

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Document No.: TAB-BAH-6656-MS-SE-00053 Rev. 00 Date: 20/04/2019
Client: DUKHAN AIR BASE PROJECT Contractor:
Contract No. C-108-1

RISK ASSESSMENT
METHOD STATEMENT FOR STEEL STRUCTURE
FABRICATION FOR BLDG 6656 – AIRCRAFT SHADES

20. out of service.

21. Ensure all valves and gauges are properly fixed.
22. Gas cylinder must be fixed with flash back arrestor.
23. Fire watcher should be present throughout the
activities and ensure fire does not occure after hot
work activities.
24. An enclosure should be provided to hold the welding
slugs and sparks.
25. Gas cylinder should be in trolley and secured.
26. Gas storage must be in well ventilated area and
maintain a safe distance for different gases.
27. Complete exhaust ventilation in all the part of the
welding area.
28. All activities should be carried out under trained,
competent supervisors.
1. Pre-start talk
2. STARRT talk
3. Apply proper manual handling techniques.
4. Rotation of works, rest/work cycle to be adopted to
eliminate repetitive exposure of manual handling.
5. Trained, authorized and competent supervisor that
must be at work place to monitor work continuously.
 Muscular skeletal 6. Suitable and sufficient PPE i.e. hand gloves, mask,
disorders and mandatory PPE shall wear.
 Cuts, abrations and 7. Place materials close to working area to reduce
6 Manual Handling 4 4 16 3 1 4 Low Y
fractures. carrying distance.
 Noise 8. Employees shall undergo training for proper Manual
Hand Arm Vibration Handling Techniques
9. Maintained good housekeeping and store material
properly.
10. Analyze the weight and size of the material,
equipment or manpower to be use.
11. Avoid manual handling if possible.
12. If manual handling can’t be avoided use mechanical
means fork lifting, cranes, hoisting, lift trucks, trolleys

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Document No.: TAB-BAH-6656-MS-SE-00053 Rev. 00 Date: 20/04/2019
Client: DUKHAN AIR BASE PROJECT Contractor:
Contract No. C-108-1

RISK ASSESSMENT
METHOD STATEMENT FOR STEEL STRUCTURE
FABRICATION FOR BLDG 6656 – AIRCRAFT SHADES

etc.
13. Heavy manual handling tasks should be carried by
several people or the load split into smaller ones.
14. Rest/work cycle can be adopted in manual handling.
15. Competent supervision must be present to ensure all
employees are adhering to manual handling safe
work procedures.
16. In noise zone areas above 85db, ear muffs/defenders
shall be used.
17. Vibration resistant hand gloves shall used.
1. Pre-start.
2. STARRT talk.
3. Inspect tools daily prior to the use & discard
damaged tools or return to store.
4. Qualified, Authorized and Competent supervision will
be in place to monitor works at all times.
 Hazards occurred by 5. Locate your gas cylinders in trolley for both carrying
manual handling. and using purposes. Cylinders will be kept in upright
 Injuries due to violation position walve protection caps to be in place.
of the PPE procedures 6. Storage of gas cylinders allowed only in the
 Fire Explosions sources designated areas.
Fitting or material from misuse of gas 7. Flash back arrestors must be installed on both of
7 5 4 20 4 2 8 Medium Y
assembly cylinders hose and cylinder valve.
 Fall of materials while 8. Correct types of fire extinguishers shall be provided.
doing minor lifts by 9. Safe lifting procedures shall be followed for every
crane. kind of lifting, independent from tonnage.
 Fire during welding/ 10. Inspect cables, hoses and connections for damage
fitting works. or leaks. Replace /repair damage cables, hose and
connection prior to work start. Use proper
connections or fitting only.
11. Provision of hot work permit to work system.
12. Combustibles and flammables and oxy/acetylene
gas cylinders and hoses should not be in contact
with hot metals or flying and falling hot molten metal

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Document No.: TAB-BAH-6656-MS-SE-00053 Rev. 00 Date: 20/04/2019
Client: DUKHAN AIR BASE PROJECT Contractor:
Contract No. C-108-1

RISK ASSESSMENT
METHOD STATEMENT FOR STEEL STRUCTURE
FABRICATION FOR BLDG 6656 – AIRCRAFT SHADES

slag.
13. Use proper PPE (Dark glasses, welding mask,
leather gloves, coverall, safety shoes, hardhat,
welding apron, leggings and arm protection.
14. Whenever possible Use mechanical means for
lifting.
1. Pre start talks/STARRT talks.
 Unplanned release or 2. Qualified, competent and authorized Supervision
dropping of load present at all times to monitor employees.
 Striking by falling 3. Suitable and sufficient PPE i.e. hand gloves, mask,
objects and mandatory PPE shall wear.
 Trapping between 4. Maintained good housekeeping and store material
fixture and load properly
 Damage to equipment 5. Operation to be planned to ensure maximum safety
or property of personnel and property.
 Striking/arching of 6. Lifting equipment is subject to a planned
overload lines maintenance programmed.
 Persons involved are 7. Current certificates or copies must be available for
not competent 5 5 25 inspection for both lifting equipment. 4 2 8 Medium Y
8 Lifting activities
 Faulty equipment. 8. All lifting equipment and accessories must be
 Lack of accurate marked with safe working load.
information about the 9. No persons are allowed to stand or work within the
load characteristics. lifting materials.
 Unstable ground where 10. Loads must not be slewed over personnel, plant,
mobile cranes are used. site huts or property.
 Poor slinging of the 11. The lifting appliance must be on firm, level base.
load. 12. Slings must not be placed on sharp edge
 Production pressure to 13. Check the condition of slings, chains and clamps
get the job on time. before to use.
14. Mandatory provision of lifting permit.

Title: Risk Assessment for MS for Steel Structure Fabrication for Bldg 6656 – Aircraft Shades Page(s):12 of 40
Document No.: TAB-BAH-6656-MS-SE-00053 Rev. 00 Date: 20/04/2019
Client: DUKHAN AIR BASE PROJECT Contractor:
Contract No. C-108-1

RISK ASSESSMENT
METHOD STATEMENT FOR STEEL STRUCTURE
FABRICATION FOR BLDG 6656 – AIRCRAFT SHADES

1. Pre-start
2. STARRT talk
3. Regular inspections by concerned supervisor &
operator before use.
4. Only trained, authorized and competent persons are
allowed to use welding machine & power tools with
required PPE (Dark glasses, welding mask, leather
gloves, coverall, safety shoes, hardhat, welding
apron, leggings and arm protection.
5. Check electrical leads & plugs for damage.
6. Use power tools based on manufacturer’s
specification.
 Fire/ Explosion 7. Do not modify tools or removed guards
 Storage of welding 8. Do not carry tools by the lead.
consumables 9. Qualified, authorized and competent supervision will
 Storage of welding be in place to monitor works at all times.
consumables. 10. Follow cable management to avoid slips and trips
 Gases, fumes or smoke 5 3 15 hazards. 4 2 4 Medium Y
9 Final Welding generated during 11. Conduct daily housekeeping on the floor. Remove
welding all the flammable materials such as wood, paper,
 Finishing welding nylon, etc.
activity (Grinding, 12. Remove combustible materials from the places
gouging) where flying sparks create ignition.
13. Sufficient number of fire extinguisher shall be
provided in the working area.
14. Specific areas shall be designated for operation
involving flammable materials. Such areas shall be
effectively controlled by means of a suitable
ventilation or exhaust hood and extraction system.
15. In confined spaces or when welding coated metal,
such galvanized steel, local exhaust ventilation shall
be provided and the hood or suction head will be
placed as near to the point at which work is being
performed as its practicable.
16. Ensure complete ventilation on the welding area,

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Document No.: TAB-BAH-6656-MS-SE-00053 Rev. 00 Date: 20/04/2019
Client: DUKHAN AIR BASE PROJECT Contractor:
Contract No. C-108-1

RISK ASSESSMENT
METHOD STATEMENT FOR STEEL STRUCTURE
FABRICATION FOR BLDG 6656 – AIRCRAFT SHADES

maintaining by circulation of fresh air, and for

rendering harmless for all fumes, dust and other
impurities generated in the work carried on the
factory.
17. Provision of hot work permit to work system
18. Great care shall be taken to protect employees from
harmful effects of the vapor or other impurities
generated on the working area.
19. Use correct type of PPE such as face shields for
grinding activities.
20. Visitors shall be provided with a protective spectacle
when touring the welding areas.
21. Warn the other contractors, visitors on the working
area to keep them away until welding or grinding
ends.
1. STARRT & RAMS to be discussed with all the
 Fall of material to be involved team
tested. 2. Qualified, authorized and competent supervision will
 Fall of NDT equipments be in place to monitor works at all times.
or tools. 3. All the materials to be tested shall be placed in
NDT Works  Skin Infections adequate working area to ensure that the NDT
a. Spray NDT  Inflammation personnel can freely moving and protected.
consumables (White  Inhalation 4. Use mandatory PPE
contrast/cleaner, Black  Ingestion 5. NDT equipment, tools, cans to be in place.
10 Ink developer)  Fire 4 3 12
6. Provision of NDT Test permit to work system
3 1 3 Low Y
b. NDT Equipment  Health hazard 7. NDT technician, third party witnesses who will
(MPI-Yoke, UT  Electrical shock and conduct welding test shall be wear with adequate
Machine) electrocution PPE
 Eye injuries from dust, 9. Operatives to be aware or others working in close
swarf or other proximity particularly when chemical spraying.
fragments 10. Maintain safe distances from energized electrical
 Hand/Arm Vibration equipment or utility lines
Syndrome (HAVS) 11. Keep tools and equipment, and their safety features,
in good working order
12. Work area to be kept clear of all combustible debris

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Document No.: TAB-BAH-6656-MS-SE-00053 Rev. 00 Date: 20/04/2019
Client: DUKHAN AIR BASE PROJECT Contractor:
Contract No. C-108-1

RISK ASSESSMENT
METHOD STATEMENT FOR STEEL STRUCTURE
FABRICATION FOR BLDG 6656 – AIRCRAFT SHADES

and materials Appropriate respiratory masks with

cartridge and eye protection to be worn full time in the
NDT testing zone.
13. Adequate signage to be displayed to restrict
unauthorized entry.
14. Keep work areas clear of clutter and equipment and
equipment stored safely when not in use
15. Maintain good ventilation during NDT process
16. Perform all movements smoothly, in a controlled,
balanced, comfortable position.
17. Dispose all the empty cans or waste materials and
scraps appropriately.
18. Operatives not to eat or drink in the NDT testing
area.
19. Wear appropriate personal protective equipment
and footwear
20. Ensure that the power tool has a current inspection
tag otherwise immediately return to store.
21. Adequate and appropriate PPE must be used by the
working personnel.
22. Ensure to have adequate numbers of Fire fighting
equipment in place. All hand tools and power tools
shall be inspected by competent person and to be
color coded as per project quarterly safe color code
system.
23. All electrical cable should be routed in safe manner.
such as keeping at proper level.
24. All the damaged tools shall be removed from work
zone and to be handover to stores. Inspect equipment
cables. Damaged cable or connection shall be
replace /repair prior to work start.

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Document No.: TAB-BAH-6656-MS-SE-00053 Rev. 00 Date: 20/04/2019
Client: DUKHAN AIR BASE PROJECT Contractor:
Contract No. C-108-1

RISK ASSESSMENT
METHOD STATEMENT FOR STEEL STRUCTURE
FABRICATION FOR BLDG 6656 – AIRCRAFT SHADES

1. Make sure that all new people must be inducted for

awareness of site safety rules and access and
egress.
2. Pre-start talk
3. STARRT talk
4. Provision of safe access & egress at workplace
5. Access way safe and correctly fixed with out any
obstruction.
6. Access way clearly visible and sign posted.
7. STARRT and/or RAMS discussed to all persons
involved in the task prior to work commencing.
 Eye injuries from dust, 8. Trained, competent and authorized Supervision
swarf or other present at all times to ensure employees are
fragments adhering to the safe working procedures. Specific
 Noise areas shall be designated for operation involving
flammable materials. Such areas shall be effectively
 Hand/Arm Vibration
“Provision of controlled by means of a suitable ventilation or
11 Syndrome (HAVS)
respiratory protection” 4 4 16 exhaust hood and extraction system. 3 1 3 Low Y
 Embolism from air
(Abrasive Blasting) 9. In confined spaces or when blasting facility, local
penetrating the skin
exhaust ventilation shall be provided and the hood or
 Health hazard suction head will be placed as near to the point at
 Dust particle from which work is being performed as its practicable.
inhaling air 10. Ensure complete ventilation on the blasting area,
 Contaminated area maintaining by circulation of fresh air, and for
rendering harmless for all dust and other impurities
generated in the work carried on the factory.
11. Respirators, fitted with the appropriate cartridge, shall
be worn by spray painters, de-greasers, epoxy
dippers or any other employee exposed to toxic,
corrosive, or other harmful vapors, mists or dusts.
12. Pre-filters shall always be used when spray painting.
These shall be replaced frequently
13. Keep unprotected workers out of the blasting area
14. Before blasting, ensure to check fittings and hose for
wear, safety-wire couplings together, helmet filters

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Document No.: TAB-BAH-6656-MS-SE-00053 Rev. 00 Date: 20/04/2019
Client: DUKHAN AIR BASE PROJECT Contractor:
Contract No. C-108-1

RISK ASSESSMENT
METHOD STATEMENT FOR STEEL STRUCTURE
FABRICATION FOR BLDG 6656 – AIRCRAFT SHADES

and air supply, pop-up valve for alignment, test

remote controls.
15. Face and eyes should to be protected. The respirator
lens provides protection to EN 166(low energy
impact). Wear appropriate safety glasses or goggles if
higher protection levels are required.
16. Respirator is designed to provide limited head
protection by reducing the force of falling objects
striking the top of the helmet.
17. The low flow indicator must be checked periodically
while the respirator is in use.
18. Air pressure must be continually monitor at the point –
of-attachment while operating this respirator. A
reliable air pressure gauge must be present to permit
you to continually monitor the pressure during actual
respirator operation.
19. Do not leave respirator in work area. Respirable dust
contaminants can remain suspended in the air for
more the one hour after work activity ceases, even
though you may no see them.
20. Proper work practice requires you to wear the
respirator until you are outside the contaminated area.
21. Failure to don, doff and store the respirator outside
the contaminated area could result in exposure to
contaminates.
22. Before donning, make sure there is no dirts, dust or
contamination inside the helmet.
23. During use, periodically check the flow indicator at the
belt to assure that adequate air flow is being supplied
to helmet.
24. When finished working, leave work area wearing
respirator and with air flowing. Once outside
contaminated area, remove respirator and then
disconnect the air supply hose using the quick-
disconnection fittings.

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Document No.: TAB-BAH-6656-MS-SE-00053 Rev. 00 Date: 20/04/2019
Client: DUKHAN AIR BASE PROJECT Contractor:
Contract No. C-108-1

RISK ASSESSMENT
METHOD STATEMENT FOR STEEL STRUCTURE
FABRICATION FOR BLDG 6656 – AIRCRAFT SHADES

25. Inspect all components if respirator system daily for

signs of wear, tear or damage that might reduce the
degree of protection originally provided.
26. The respirator should be cleaned and sanitized at
least weekly, more often if subjected to heavy use.
27. Helmets used by more than one person must be
cleaned, inspected and sanitized after each use. If not
cleaned, contamination may cause illness or disease.
28. After reusable respirator components have been
cleaned, dried and inspected, place them in a plastic
bag or an airtight container.
29. Store the respirator and parts where they will be
protected from contamination, distortion and damage
from elements such as dust, direct sunlight, heat,
extreme cold, excessive moisture and harmful
chemicals.

1. Pre-start talk to be carried out to all work force

 Slips, trips and falls involved.
Surface preparation  Eye injuries from dust, 2. 'Trained, Competent and Authorized operatives are
a. Grinding/Sanding) swarf or other fragments allowed to use power tools.
b. Usage of Power  Wrist and hand injuries 3. Qualified, Competent and Authorized electricians to
Tools due to tool jamming or test all portable electrical equipment at recommended
c. Blasting Works- binding regular intervals.
4. Employee conducts daily inspections of power tools
Automatic & manual  Noise
12 (Including electrical cords) before operation and
Blasting  Hand/Arm Vibration 5 5 25 4 1 4 Low Y
where faults are identified that require immediate
d. Lifting activity using Syndrome (HAVS)
maintenance the tool is put out of service until
overhead crane during  Fire / Explosion maintenance is conducted by a Trained, Competent
surface preparation  Embolism from air and Authorized person.
e. Use of penetrating the skin 5. All power feeds, electrical, pneumatic or hydraulic, to
equipment/loader  Health hazard comply with Qatar National Standards and maintained
 Electrical shock and in good condition.
electrocution 6. Ensure that the power tool has the correct guard,
shield or other attachment that the manufacturer

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Document No.: TAB-BAH-6656-MS-SE-00053 Rev. 00 Date: 20/04/2019
Client: DUKHAN AIR BASE PROJECT Contractor:
Contract No. C-108-1

RISK ASSESSMENT
METHOD STATEMENT FOR STEEL STRUCTURE
FABRICATION FOR BLDG 6656 – AIRCRAFT SHADES

recommends. Ensure all electrical distribution boards

are fitted with ELCB and this is regularly tested to
evaluate if it is working safely or not with immediate
rectification of faults.
7. Ensure power tools have appropriate earthing.
8. Relevant Permit to work should be obtained prior to
the start of work.
9. Tools must be used accordance with manufactures
instruction. Select power tools with lowest vibration
level. A tool producing high levels of vibration to have
anti-vibration handles to reduce the risks.
10. Minimize the time individuals use the equipment, i.e
Job rotation.
11. Noise assessment required where deemed
necessary.
12. A safe working platform is required when using a
power tool.
13. Power tools shall only be used in well-lit and
ventilated area.
14. Wear or use personal protective equipment (PPE) or
clothing that is appropriate for the work you are doing
this may include, items such as safety glasses or
goggles or face shield ( with glasses or
goggles),hearing protection, dust mask, gloves, safety
boots or shoes or rubber boots.
15. Switch off the tools before connecting them to a
power supply.
16. If the power cord feels more than comfortably warm or
if a tool is sparking, have it checked by an electrician
or other qualified person.
17. Disconnect the power supply before making
adjustments or changing accessories.
18. Remove any wrenches and adjusting tools before
turning on a tool.
19. Inspect the cord for fraying or damage before each

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Document No.: TAB-BAH-6656-MS-SE-00053 Rev. 00 Date: 20/04/2019
Client: DUKHAN AIR BASE PROJECT Contractor:
Contract No. C-108-1

RISK ASSESSMENT
METHOD STATEMENT FOR STEEL STRUCTURE
FABRICATION FOR BLDG 6656 – AIRCRAFT SHADES

use. Tag defective tools must be immediately

returned to the store man.
20. During use, keep power cords clear of tools and the
path that the tool will take.
21. Use clamps, a vice or other devices to hold and
support the piece being worked on, when practical to
do so. This will allow you to use both hands for better
control of the tool and will help prevent injuries if a
tool jams or binds in a work piece.
22. Use only approved extension cords that have the
proper wire size (gauge) for the length of cord and
power requirements of the electric tool that you are
using. This will prevent the cord from overheating.
23. Suspend power cords over aisles or work areas to
eliminate stumbling or tripping hazards.
24. Eliminate octopus connections: if more than one
receptacle plug is needed, use a power bar or power
distribution strip that has an integral power cord and a
built-in over current protection.
25. Pull the plug, not the cord when unplugging a tool.
Pulling the cord causes wear and may adversely
affect the wiring to the plug and cause electrical shock
to the operator.
26. Follow good housekeeping procedures - keep the
work area free of clutter and debris that could be
tripping or slipping hazards.
27. Keep power cords away from heat, water, oil, sharp
edges and moving parts. They can damage the
insulation and cause a shock.
28. Ensure that cutting tools, drill bits, etc. are kept sharp,
clean and well maintained.
29. Store tools in a dry, secure location when they are not
being used. Do not wear gloves, loose clothing or
jewelry while using revolving power tools. Tie back
long hair or wear appropriate hair protection to

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Document No.: TAB-BAH-6656-MS-SE-00053 Rev. 00 Date: 20/04/2019
Client: DUKHAN AIR BASE PROJECT Contractor:
Contract No. C-108-1

RISK ASSESSMENT
METHOD STATEMENT FOR STEEL STRUCTURE
FABRICATION FOR BLDG 6656 – AIRCRAFT SHADES

prevent hair from getting caught in moving parts of

equipment.
30. Do not wear gloves, loose clothing or jewelry while
using revolving power tools. Tie back long hair or
wear appropriate hair protection to prevent hair from
getting caught in moving parts of equipment.
31. Do not leave a running tool unattended. Do not leave
it until it has been turned off, has stopped running
completely, and has been unplugged
32. Do not expose electric power tools to rain or wet
conditions; wet tools increase the likelihood of electric
shock.
33. Stop using an electric power tool if you feel a tingle in
your fingers. This is a warning that the tool is faulty
and needs repair.
34. Prevent shocks. Ensure that the tools are properly
grounded using an industrial type three-prong plug,
are double-insulated (and are labeled as such), or
are powered by a low-voltage isolation transformer:
this will protect users from an electrical shock, i.e.
110 voltage.
35. Do not walk on or allow vehicles or other moving
equipment to pass over unprotected power cords.
Cords should be put in conduits or protected by
placing planks on each side of them.
36. Do not operate tools in an area containing explosive
vapours or gases.
37. Do not clean tools with flammable or toxic solvents.
38. Do not surprise or touch anyone who is operating a
tool. Startling a tool operator could end up causing
an accident or injury.
39. Trained, Competent and Authorized Supervision
present at all times to ensure employees are
adhering to working at height safe working
procedures.

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Document No.: TAB-BAH-6656-MS-SE-00053 Rev. 00 Date: 20/04/2019
Client: DUKHAN AIR BASE PROJECT Contractor:
Contract No. C-108-1

RISK ASSESSMENT
METHOD STATEMENT FOR STEEL STRUCTURE
FABRICATION FOR BLDG 6656 – AIRCRAFT SHADES

40. While blasting protective filter should be worn over

mouth and nose.
41. Leather gloves and aprons to be used.
42. The ankle and wrist opening should be wrapped in
duct tape to prevent sand entering the suit.
43. Blaster nozzle must have automatic shut off fixed.
44. Hose whip restraints must be fitted.
45. Earthing should be done for static electricity.
46. Containment of dust and over blasts
47. Clean up required after completion
48. Washing / showering facility required
49. Blasting work area to be isolated / barricaded and
proper signage should be in place.
50. Disposal methods for all waste materials should be as
per the Environment management plan.

 Fire / Explosion 1. Ensure STARRT and/or RAMS are discussed with the
 Manual Handling work group prior to works commencing
 Risk of eye injury 2. Trained, Competent and Authorized Supervision
present at all times to monitor employees.
 Slips, Trips and Falls
3. Alternatives safer products (paints/varnishes/solvents)
 Working in confined
Coating and Painting to be considered, i.e. water based painted used as a
spaces
works replacement to lead based paints
 Lifting heavy or awkward
4. MSDS sheets to be discussed with all persons
a. Spray Painting objects
involved in the task prior to works commencing
13 Application  Standing for long 5 5 25 5. Adequate welfare facilities including skin cleaners and 3 2 6 Medium Y
b. Lifting activity using periods of time hot/warm water to be provided.
overhead crane.  Risk of Injury due to 6. Operatives to be aware or others working in close
c. Use of falling proximity particularly when paint spraying.
equipment/loader  Exposure to heat and 7. All paint and varnish tins, etc. to be properly secured
ultraviolet radiation from and stored in approved and properly ventilated
outdoor works containers with appropriate warning signs and
 Working in awkward security arrangements.
positions or performing 8. No smoking or naked flames in painting area.
repetitive physical tasks 9. Select the correct ladder for the job. Ladder use is

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Document No.: TAB-BAH-6656-MS-SE-00053 Rev. 00 Date: 20/04/2019
Client: DUKHAN AIR BASE PROJECT Contractor:
Contract No. C-108-1

RISK ASSESSMENT
METHOD STATEMENT FOR STEEL STRUCTURE
FABRICATION FOR BLDG 6656 – AIRCRAFT SHADES

 Health hazard intended for short term work only, i.e. 5-10 minutes. If
 Exposure to pain the work will last longer than this time period then a
products, solvents, lead, safe platform is to be erected.
and other toxic 10. If scaffolds are to be used these must be erected and
substances assessed by Qualified, Competent and Authorized
 Working close to live persons only
electrical power lines or 11. If elevator work platform or other similar mechanical
equipment equipment will be used ensure these have a valid 3rd
 Stress and increased party certificate and are only operated by someone
risk of injury and disease whom has the appropriate type of license and valid
from shift work or 3rd party certification.
extended work days 12. Avoid awkward body positions or take frequent breaks
 Working at heights and 13. Minimal repetitive bending, twisting and overreaching
on ladders, platforms movements
and scaffolds, with 14. Employees are provided with the correct lifting /
attendant risks of falls handling techniques
15. Maintain safe distances from energized electrical
equipment or utility lines
16. Keep tools and equipment, and their safety features,
in good working order
17. Work area to be kept clear of all combustible debris
and materials
18. Keep work areas clear of clutter and equipment and
equipment stored safely when not in use.
1. STARRT & RAMS to be discussed with all the
involved team
 Eye Injury 2. All the involved operatives to be assured competent/
 Skin Infections trained and suitable for the task.
 Inflammation 3. Air compressor used for spray painting shall be
14 Spray Painting  Inhalation 5 5 25 securely placed with adequate guarding and enclosed 3 1 3 Low Y
 Ingestion with barricades and signboards.
 Fire 4. All rotatory parts shall be adequately covered.
 Spill 5. Air hose couplers shall be secured adequately with
whiplash arrestors.
6. Work rotation shall be done timeously in order to

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Document No.: TAB-BAH-6656-MS-SE-00053 Rev. 00 Date: 20/04/2019
Client: DUKHAN AIR BASE PROJECT Contractor:
Contract No. C-108-1

RISK ASSESSMENT
METHOD STATEMENT FOR STEEL STRUCTURE
FABRICATION FOR BLDG 6656 – AIRCRAFT SHADES

minimize the exposure time.

7. Adequate ventilation in the spray-painting zone.
8. Appropriate respiratory masks with cartridge and eye
protection to be worn full time in the painting zone.
9. Adequate signage to be displayed to restrict
unauthorized entry.
10. Full PPE’S which includes disposable coverall,
Cartridge mask, Goggles, Steel toed shoes etc.
11. Adequate firefighting equipment to be in place nearby
the work zone.
12. MSDS of the chemicals to be displayed
13. Paints/Thinners shall not kept exposed to sunlight
need to be secured as per MSDS.
14. All the waste disposal shall be done as per MSDS
recommendation.
15. Close and proficient work supervision shall be
presence all the time.
16. Pre checklists to be regularly maintained.
17. All hand tools and power tools shall be inspected by
competent person and to be color coded as per
project quarterly safe color code system.
18. All the damaged tools shall be removed from work
zone and to be handover to stores.
1. Equipment and operator competency certification.
2. Daily TBT for the operator regarding site traffic
regulations and associated hazards.
 Traffic accident 3. Competent Banksman to be assigned all time with
 Collision with other operational equipment.
15 Use of equipment equipment 4. Designated access and signs to be in place.
4 4 16 3 1 3 Low Y
(Loader)  Hit personal 5. Traffic signs to be clearly marked.
 Serious personal 6. Equipment shall be well maintained and to be
Injuries inspected periodically by competent person.
7. Work supervisor shall ensure, NO over loading of
material in the equipment.
8. Loose materials Debris shall be adequately secured

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Document No.: TAB-BAH-6656-MS-SE-00053 Rev. 00 Date: 20/04/2019
Client: DUKHAN AIR BASE PROJECT Contractor:
Contract No. C-108-1

RISK ASSESSMENT
METHOD STATEMENT FOR STEEL STRUCTURE
FABRICATION FOR BLDG 6656 – AIRCRAFT SHADES

and covered while transportation.

9. Proficient work supervision shall be full time available
in site.
10. All incidents and near misses shall be timely reported
to the concern.
11. Operational manual shall be always kept in
equipment.

1. Pre start talks/STARRT talks.

 Unplanned release or 2. Qualified, competent and authorized Supervision
dropping of load present at all times to monitor employees.
 Damage to equipment 3. Suitable and sufficient PPE i.e. hand gloves, mask,
or property and mandatory PPE shall wear.
 Striking/arching of 4. Operation to be planned to ensure maximum safety of
overload lines personnel and property.
 Persons involved are 5. Lifting equipment is subject to a planned maintenance
not competent programmed.
 Faulty equipment. 6. Current certificates or copies must be available for
 Lack of accurate inspection for both lifting equipment.
Use of Plant information about 7. All equipment and accessories must be marked with
Equipment inside the machine characteristics. safe working performance.
16 plant  Unstable ground where 5 5 25 8. No persons are allowed to use any plant equipment 4 2 8 Medium Y
mobile cranes are used. without authorization of Supervisor and safety officer
 Injuries due to violation 9. Equipment will be in good order & regularly
of the PPE procedures maintained
 Fire Explosions sources 10. Preventive maintenance for all machines, gas
from misuse of gas cylinders, compressors and other various type of
cylinders machines as mentioned in section 4.2 of Method
 Fall of materials while statement
doing minor lifts by 14. Great care shall be taken to protect employees from
crane. harmful effects of the vapor or other impurities
Fire during generated on the working area.
welding/fitting works 15. Ensure power tools have appropriate earthing.
16. Relevant Permit to work should be obtained prior to
the start of work.

Title: Risk Assessment for MS for Steel Structure Fabrication for Bldg 6656 – Aircraft Shades Page(s):25 of 40
Document No.: TAB-BAH-6656-MS-SE-00053 Rev. 00 Date: 20/04/2019
Client: DUKHAN AIR BASE PROJECT Contractor:
Contract No. C-108-1

RISK ASSESSMENT
METHOD STATEMENT FOR STEEL STRUCTURE
FABRICATION FOR BLDG 6656 – AIRCRAFT SHADES

17. Tools must be used accordance with manufactures

instruction. Select power tools with lowest vibration
level. A tool producing high levels of vibration to have
anti-vibration handles to reduce the risks.
18. Minimize the time individuals use the equipment, i.e
Job rotation.
19. Noise assessment required where deemed
necessary.
20. A safe working platform is required when using a
power tool.
21. Power tools shall only be used in well-lit and
ventilated area.
22. Wear or use personal protective equipment (PPE) or
clothing that is appropriate for the work you are doing
this may include, items such as safety glasses or
goggles or face shield (with glasses or goggles),
hearing protection, dust mask, gloves, safety boots or
shoes or rubber boots.
23. Switch off the tools before connecting them to a
power supply.
24. If the power cord feels more than comfortably warm or
if a tool is sparking, have it checked by an electrician
or other qualified person.
25. Disconnect the power supply before making
adjustments or changing accessories.
26. Remove any wrenches and adjusting tools before
turning on a tool.
27. Inspect the cord for fraying or damage before each
use. Tag defective tools must be immediately
returned to the store man.
28. During use, keep power cords clear of tools and the
path that the tool will take.
29. Use clamps, a vice or other devices to hold and
support the piece being worked on, when practical to
do so. This will allow you to use both hands for better

Title: Risk Assessment for MS for Steel Structure Fabrication for Bldg 6656 – Aircraft Shades Page(s):26 of 40
Document No.: TAB-BAH-6656-MS-SE-00053 Rev. 00 Date: 20/04/2019
Client: DUKHAN AIR BASE PROJECT Contractor:
Contract No. C-108-1

RISK ASSESSMENT
METHOD STATEMENT FOR STEEL STRUCTURE
FABRICATION FOR BLDG 6656 – AIRCRAFT SHADES

control of the tool and will help prevent injuries if a

tool jams or binds in a work piece.
30. Use only approved extension cords that have the
proper wire size (gauge) for the length of cord and
power requirements of the electric tool that you are
using. This will prevent the cord from overheating.
31. Suspend power cords over aisles or work areas to
eliminate stumbling or tripping hazards.
32. Eliminate octopus connections: if more than one
receptacle plug is needed, use a power bar or power
distribution strip that has an integral power cord and a
built-in over current protection.
33. Pull the plug, not the cord when unplugging a tool.
Pulling the cord causes wear and may adversely
affect the wiring to the plug and cause electrical shock
to the operator.
34. Follow good housekeeping procedures - keep the
work area free of clutter and debris that could be
tripping or slipping hazards.
35. Keep power cords away from heat, water, oil, sharp
edges and moving parts. They can damage the
insulation and cause a shock.
36. Ensure that cutting tools, drill bits, etc. are kept sharp,
clean and well maintained.
37. Store tools in a dry, secure location when they are not
being used.
38. Do not wear gloves, loose clothing or jewelry while
using revolving power tools. Tie back long hair or
wear appropriate hair protection to prevent hair from
getting caught in moving parts of equipment.
39. Do not leave a running tool unattended. Do not leave
it until it has been turned off, has stopped running
completely, and has been unplugged
40. Do not expose electric power tools to rain or wet
conditions; wet tools increase the likelihood of electric

Title: Risk Assessment for MS for Steel Structure Fabrication for Bldg 6656 – Aircraft Shades Page(s):27 of 40
Document No.: TAB-BAH-6656-MS-SE-00053 Rev. 00 Date: 20/04/2019
Client: DUKHAN AIR BASE PROJECT Contractor:
Contract No. C-108-1

RISK ASSESSMENT
METHOD STATEMENT FOR STEEL STRUCTURE
FABRICATION FOR BLDG 6656 – AIRCRAFT SHADES

shock.
41. Stop using an electric power tool if you feel a tingle in
your fingers. This is a warning that the tool is faulty
and needs repair.
42. Prevent shocks. Ensure that the tools are properly
grounded using an industrial type three-prong plug,
are double-insulated (and are labeled as such), or
are powered by a low-voltage isolation transformer:
this will protect users from an electrical shock, i.e.
110 voltage.
43. Do not walk on or allow vehicles or other moving
equipment to pass over unprotected power cords.
Cords should be put in conduits or protected by
placing planks on each side of them.
44. Do not operate tools in an area containing explosive
vapours or gases.
45. Do not clean tools with flammable or toxic solvents.
46. Do not surprise or touch anyone who is operating a
tool. Startling a tool operator could end up causing
an accident or injury.
47. Trained, Competent and Authorized Supervision
present at all times to ensure employees are
adhering to working at height safe working
procedures.
48. While blasting protective filter should be worn over
mouth and nose.
49. Leather gloves and aprons to be used.
50. The ankle and wrist opening should be wrapped in
duct tape to prevent sand entering the suit.
51. Blaster nozzle must have automatic shut off fixed.
52. Hose whip restraints must be fitted.
53. Earthing should be done for static electricity.
54. Containment of dust and over blasts
55. Clean up required after completion
56. Washing / showering facility required

Title: Risk Assessment for MS for Steel Structure Fabrication for Bldg 6656 – Aircraft Shades Page(s):28 of 40
Document No.: TAB-BAH-6656-MS-SE-00053 Rev. 00 Date: 20/04/2019
Client: DUKHAN AIR BASE PROJECT Contractor:
Contract No. C-108-1

RISK ASSESSMENT
METHOD STATEMENT FOR STEEL STRUCTURE
FABRICATION FOR BLDG 6656 – AIRCRAFT SHADES

57. Blasting work area to be isolated / barricaded and

proper signage should be in place.
58. Disposal methods for all waste materials should be as
per the Environment management plan.

1. Pre start talks/STARRT talks.

2. Qualified, competent and authorized Supervision
 Unplanned release or present at all times to monitor employees.
dropping of load 3. Suitable and sufficient PPE i.e. hand gloves, mask,
 Damage to equipment and mandatory PPE shall wear.
or property 4. Operation to be planned to ensure maximum safety of
 Striking/arching of personnel and property.
overload lines 5. Lifting equipment is subject to a planned maintenance
 Persons involved are programme.
not competent 6. Current certificates or copies must be available for
inspection for both lifting equipment.
 Faulty equipment.
7. All equipment and accessories must be marked with
 Lack of accurate
safe working performance.
information about
Activities use of 8. No persons are allowed to use any plant equipment
machine characteristics.
17 Compressor without authorization of Supervisor and safety officer
 Unstable ground where 5 5 25 4 2 8 Medium Y
10. Equipment will be in good order & regularly
mobile cranes are used. maintained
 Injuries due to violation 11. Maintenance preventive maintenance for all
of the PPE procedures machines, gas cylinders, compressors and other
 Fire Explosions sources various type of machines as mentioned in section 4.2
from misuse of gas of Method statement
cylinders 12. Great care shall be taken to protect employees from
 Fall of materials while harmful effects of the vapor or other impurities
doing minor lifts by generated on the working area.
crane. 13. Compressor must be used accordance with
 Fire during manufactures instruction. Select power tools with
welding/fitting works lowest vibration level. A tool producting high levels of
vibration to have anti-vibration handles to reduce the
risks.
14. Noise assessment required where deemed
Title: Risk Assessment for MS for Steel Structure Fabrication for Bldg 6656 – Aircraft Shades Page(s):29 of 40
Document No.: TAB-BAH-6656-MS-SE-00053 Rev. 00 Date: 20/04/2019
Client: DUKHAN AIR BASE PROJECT Contractor:
Contract No. C-108-1

RISK ASSESSMENT
METHOD STATEMENT FOR STEEL STRUCTURE
FABRICATION FOR BLDG 6656 – AIRCRAFT SHADES

necessary.
15. A safe working platform is required when using a
power tool.
16. Wear or use personal protective equipment (PPE) or
clothing that is appropriate for the work you are doing
this may include, items such as safety glasses or
goggles or face shield ( with glasses or
goggles),hearing protection, dust mask, gloves, safety
boots or shoes or rubber boots.

 Unplanned release or 1. Pre start talks/STARRT talks.

dropping of load 2. Qualified, competent and authorized Supervision
 Damage to equipment present at all times to monitor employees.
or property 3. Suitable and sufficient PPE i.e. hand gloves, mask,
 Striking/arching of and mandatory PPE shall wear.
overload lines 4. Operation to be planned to ensure maximum safety of
 Persons involved are personnel and property.
not competent 5. Lifting equipment is subject to a planned maintenance
 Faulty equipment. programmed.
 Lack of accurate 6. Current certificates or copies must be available for
information about inspection for both lifting equipment.
Activities use of machine characteristics. 7. All equipment and accessories must be marked with
18 Compressed gas  Unstable ground where 5 5 25 safe working performance. 4 2 8 Medium Y
cylinder mobile cranes are used. 8. No persons are allowed to use any plant equipment
 Injuries due to violation without authorization of Supervisor and safety officer
of the PPE procedures 9. Equipment will be in good order & regularly
 Fire Explosions sources maintained
from misuse of gas 10. Maintenance preventive maintenance for all
cylinders machines, gas cylinders, compressors and other
 Fall of materials while various type of machines as mentioned in section 4.2
doing minor lifts by of Method statement
crane. 11. Great care shall be taken to protect employees from
Fire during harmful effects of the vapor or other impurities
welding/fitting works generated on the working area.
12. Ensure power tools have appropriate earthing.

Title: Risk Assessment for MS for Steel Structure Fabrication for Bldg 6656 – Aircraft Shades Page(s):30 of 40
Document No.: TAB-BAH-6656-MS-SE-00053 Rev. 00 Date: 20/04/2019
Client: DUKHAN AIR BASE PROJECT Contractor:
Contract No. C-108-1

RISK ASSESSMENT
METHOD STATEMENT FOR STEEL STRUCTURE
FABRICATION FOR BLDG 6656 – AIRCRAFT SHADES

13. Relevant Permit to work should be obtained prior to

the start of work.
14. Tools must be used accordance with manufactures
instruction. Select power tools with lowest vibration
level. A tool producting high levels of vibration to have
anti-vibration handles to reduce the risks.
15. Minimize the time individuals use the equipment, i.e
Job rotation.
16. Noise assessment required where deemed
necessary.
17. A safe working platform is required when using a
power tool.
18. Power tools shall only be used in well-lit and
ventilated area.
19. Wear or use personal protective equipment (PPE) or
clothing that is appropriate for the work you are doing
this may include, items such as safety glasses or
goggles or face shield (with glasses or
goggles),hearing protection, dust mask, gloves, safety
boots or shoes or rubber boots.

1. STARRT & RAMS shall be communicated by

Engineer/Supervisor prior to commence the task.
 Equipment or Control 2. Acquire relevant Permit to work (Lifting)
Failure 3. Pre checklist to be strictly maintained and to be
 Impact/Crushing regularly check by competent person.
 Unexpected movement 4. Discard/Removal of damaged tools
19 Activities use of Over  Incorrect Stacking 5. All the tools shall be inspected by competent person
5 5 25 4 2 8 Medium Y
Head Cranes  Incorrect Slinging and to be marked with quarterly color code.
 Obstructed view 6. Do not exceed safe working load.
 Falling of load 7. Equipment and Operator and lifting gears to be
 Personal Injury certified and fit for task.
 Property Damage 8. Remotes must be checked against specific cranes.
9. Periodic maintenance shall be done as per
manufacturer’s recommendation.

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Document No.: TAB-BAH-6656-MS-SE-00053 Rev. 00 Date: 20/04/2019
Client: DUKHAN AIR BASE PROJECT Contractor:
Contract No. C-108-1

RISK ASSESSMENT
METHOD STATEMENT FOR STEEL STRUCTURE
FABRICATION FOR BLDG 6656 – AIRCRAFT SHADES

10. Ensure work area is clear and access & egress allow
clear room to avoid trapping situation.
11. Emergency preparedness shall be in place nearby the
equipment operational zone.
12. Position slinging correctly and check load balance,
lower and re-sling if not balanced.
13. Ensure all material are stacked adequately and
packers are in place with good condition.
14. Riggers/slingers shall have adequate training and
certified to be competent for the task.
15. Whilst operation area shall be isolated with
unauthorized entry and shall be restrict unauthorized
entry.
16. Equipment handrails shall comply with QCS 2014
standards.
17. Full body harness shall be worn whilst climbing over
head crane.

 Slip, trips and fall 1. Pre start talks/STARRT talks.

Use of various type of
machines a.  Health hazard 2. Qualified, competent and authorized Supervision
Rollforming machines  Hit by flying particles present at all times to monitor employees.
during operation 3. Suitable and sufficient PPE i.e. hand gloves, mask,
“Z” & “C”
b. Rollforming  Electrical shock and and mandatory PPE shall wear.
electrocution 4. Operation to be planned to ensure maximum safety of
machine “Decking”
 Eye injuries from dust, personnel and property.
c. Rollforming
swarf or other fragments 5. All equipment and accessories must be marked with
20 machine “Sheeting”
 Wrist and hand injuries 4 4 16 safe working performance. 2 1 2 Low Y
d. Rollforming
due to tool jamming or 6. No persons are allowed to use any plant equipment
machine “Downspout
binding without authorization of Supervisor and safety officer
e. Curve Panel 7. Equipment will be in good order & regularly
 Hand/Arm Vibration
sheeting maintained
Syndrome (HAVS)
f. Shearing Machines 8. Preventive maintenance for all roll forming machines,
 Equipment or Control
h. Sheet Folding folding machines, shearing machines, treading
Failure
machines machines and others.
 Unexpected movement
i. Rod treading 9. Great care shall be taken to protect employees from
 Incorrect Stacking
Title: Risk Assessment for MS for Steel Structure Fabrication for Bldg 6656 – Aircraft Shades Page(s):32 of 40
Document No.: TAB-BAH-6656-MS-SE-00053 Rev. 00 Date: 20/04/2019
Client: DUKHAN AIR BASE PROJECT Contractor:
Contract No. C-108-1

RISK ASSESSMENT
METHOD STATEMENT FOR STEEL STRUCTURE
FABRICATION FOR BLDG 6656 – AIRCRAFT SHADES

machines  Serious personal harmful effects of the vapor or other impurities

Injuries generated on the working area.
 Contact with revolving 10. Tools must be used accordance with manufactures
cutter. instruction. Select power tools with lowest vibration
 Broken cutter, swarf and level. A tool production high levels of vibration to have
work pieces can be anti-vibration handles to reduce the risks.
violently ejected. 11. Minimize the time individuals use the equipment, i.e
 Sharp edge tools, work Job rotation.
pieces and swarf can 12. Operational manual shall be always kept in
cause cuts. equipment.
 Cut from lifting the 13. Switch off the machine before connecting them to a
sheets of metal. power supply.
 Contact with cutting 14. If the power cord feels more than comfortably warm or
fluids, oil and grease if a tool is sparking, have it checked by an electrician
can irritate skin. or other qualified person.
 Closing movement 15. Disconnect the power supply before making
surfaces and other parts adjustments or changing accessories.
can result in trapping 16. Remove any wrenches and adjusting tools before
and serious injury. turning on a roll forming machine/equipments.
17. Pull the plug, not the cord when unplugging a
 Sharp edges on cut can
machine. Pulling the cord causes wear and may
cause cuts.
adversely affect the wiring to the plug and cause
 Hand and finger trapped
electrical shock to the operator.
 Lack of space around 18. Follow good housekeeping procedures - keep the
the machine can lead work area free of clutter and debris that could be
operator being pushed tripping or slipping hazards.
by passers-by. 19. Keep power cords away from heat, water, oil, sharp
 Slippery floor surface or edges and moving parts. They can damage the
loose items around the insulation and cause a shock.
machine can cause slip 20. Do not leave a running tool unattended. Do not leave
that result in contact it until it has been turned off, has stopped running
with moving parts. completely, and has been unplugged
 Manual Handling of 21. Prevent shocks. Ensure that the tools are properly
sheet materials and grounded using an industrial type three-prong plug,
operating levers or are double-insulated (and are labeled as such), or

Title: Risk Assessment for MS for Steel Structure Fabrication for Bldg 6656 – Aircraft Shades Page(s):33 of 40
Document No.: TAB-BAH-6656-MS-SE-00053 Rev. 00 Date: 20/04/2019
Client: DUKHAN AIR BASE PROJECT Contractor:
Contract No. C-108-1

RISK ASSESSMENT
METHOD STATEMENT FOR STEEL STRUCTURE
FABRICATION FOR BLDG 6656 – AIRCRAFT SHADES

treadles are powered by a low-voltage isolation transformer:

 Entanglement of long this will protect users from an electrical shock, i.e.
hair and loose clothing 110 voltage.
in moving parts 22. Do not walk on or allow vehicles or other moving
equipment to pass over unprotected power cords.
Cords should be put in conduits or protected by
placing planks on each side of them.
23. Do not clean machine parts, rollers, shafting, etc.
with flammable or toxic solvents.
24. Do not surprise or touch anyone who is operating a
machine. Startling a machine operator could end up
causing an accident or injury.
25. There should be sufficient space around the
machine t prevent the operator from being
accidentally pushed by passers-by.
26. When the machine is not use, it should be made
safe by locking the action.
27. All revolving parts of roll forming machines shall be
totally enclosed to prevent fingers coming into
contact with the nip point.
28. Guard shall be removed only for adjustments or
maintenance. Such work to be carried out under
competent supervision and guards replaced
immediately after relevant repairs/adjustment are
completed.
29. Guard shall be fitted to all shears to prevent the
fingers of the operator from reaching the blade.
Such guard shall extent across the full width of the
table.
30. If the hold-downs are not individually guarded, a
barrier guard shall be positioned in front of the hold-
downs.
31. Guards shall be fixed or automatically self-adjusting
to the thickness of the metal being cut.
32. “Start” and “Stop” button shall be located within easy

Title: Risk Assessment for MS for Steel Structure Fabrication for Bldg 6656 – Aircraft Shades Page(s):34 of 40
Document No.: TAB-BAH-6656-MS-SE-00053 Rev. 00 Date: 20/04/2019
Client: DUKHAN AIR BASE PROJECT Contractor:
Contract No. C-108-1

RISK ASSESSMENT
METHOD STATEMENT FOR STEEL STRUCTURE
FABRICATION FOR BLDG 6656 – AIRCRAFT SHADES

reach of the operator.

33. No person shall be permitted to operate any
machine without adequate training.
34. No other than qualified mechanic shall ever be
permitted to make repair in all machine or to adjust
it.
35. Periodic maintenance checks shall be schedule to
ensure that mechanical parts and guards are in
proper working order.
36. No attempt shall be made to cut materials until it is
securely gripped by the hold-down tools.
Never cut more than one thickness of materials at one
time 9i.e do not “stack and shear”).
37. Never cut more than one thickness of materials at one
time 9i.e do not “stack and shear”).

 Contact with revolving 1. Pre start talks/STARRT talks.

cutter can present a 2. Qualified, competent and authorized Supervision
hazard. present at all times to monitor employees.
 Long hair and loose 3. Suitable and sufficient PPE i.e. hand gloves, mask,
clothing can become and mandatory PPE shall wear.
entangled in moving 4. Operation to be planned to ensure maximum safety of
parts of the machine. personnel and property.
Use of various type of  Broken cutter, swarf and 5. All equipment and accessories must be marked with
machines (Milling work pieces can be safe working performance.
21 Machines) violently ejected. 4 4 16 6. No persons are allowed to use any plant equipment 3 1 3 Low Y
 Sharp edge tools, work without authorization of Supervisor and safety officer
pieces and swarf can 7. Equipment will be in good order & regularly
cause cuts. Contact with maintained
cutting fluids, oil and 8. Great care shall be taken to protect employees from
grease can irritate skin. harmful effects of the vapor or other impurities
 Milling machines can generated on the working area.
present a hazard of 9. Machines must be used accordance with
electrical shock. manufactures instruction.
 Closing movement 10. Minimize the time individuals use the equipment, i.e

Title: Risk Assessment for MS for Steel Structure Fabrication for Bldg 6656 – Aircraft Shades Page(s):35 of 40
Document No.: TAB-BAH-6656-MS-SE-00053 Rev. 00 Date: 20/04/2019
Client: DUKHAN AIR BASE PROJECT Contractor:
Contract No. C-108-1

RISK ASSESSMENT
METHOD STATEMENT FOR STEEL STRUCTURE
FABRICATION FOR BLDG 6656 – AIRCRAFT SHADES

between parts, under Job rotation.

power feed, can result in 11. Noise assessment required where deemed
finger trapping. necessary.
 Heavy objects such as 12. Wear or use personal protective equipment (PPE) or
vices and index fixture clothing that is appropriate for the work you are doing
can fall from table. this may include, items such as safety glasses or
 Inadvertent starting of goggles or face shield (with glasses or goggles),
the machine can present hearing protection, dust mask, gloves, safety boots or
a hazard. shoes or rubber boots.
 Lack of space around 13. Operational manual shall be always kept in
the machine can lead equipment.
operator being pushed 14. A means of electrical isolation using a fused switch-
by passers-by. disconnector on or adjustment to machine, and that it
 Slippery floor surface or is controlled by a starter incorporating overload
loose items around the protection.
machine can cause slip 15. A conveniently positioned mushroom headed stop
that result in contact with button or other suitable control device that can quickly
moving parts. stop the machine in an emergency.
 Serious personal Injuries 16. Fixed quards, or alternative interlocked guards that
enclose the drive mechanisms.
17. Handles or hand wheel to operate the table
mechanism should be set up so that they do not
rotate when the power drive is engaged.
18. There should be sufficient space around the machine
to prevent the operator from being accidentally
pushed by passers-by.
19. Do not leave a running machine unattended. Do not
leave it until it has been turned off, has stopped
running completely, and has been unplugged
20. Eye protection(goggles) worn when operating the
machine, long hair should be tied back and protected
from entanglement.
21. Loose clothing and jewellery should be tucked in
/removed.
22. The machine should be electrically isolated before an

Title: Risk Assessment for MS for Steel Structure Fabrication for Bldg 6656 – Aircraft Shades Page(s):36 of 40
Document No.: TAB-BAH-6656-MS-SE-00053 Rev. 00 Date: 20/04/2019
Client: DUKHAN AIR BASE PROJECT Contractor:
Contract No. C-108-1

RISK ASSESSMENT
METHOD STATEMENT FOR STEEL STRUCTURE
FABRICATION FOR BLDG 6656 – AIRCRAFT SHADES

internal mechanism are adjusted.

23. Coolant nozzles should not be adjusted while the
machine is in operation.
24. Suitable implements should be used to removed
swarf to avoid hand contact.
25. Swarf should not be allowed to accumulate as it
become entangled or ejected by chuck or work piece.
Swarf will not be removed while the machine is
operating.
26. Contact with the skin should be kept to a minimum.
Hands should be washed thoroughly after using the
machine.

 Chuck key, broken drills, 1. Pre start talks/STARRT talks.

work pieces, etc. can 2. Qualified, competent and authorized Supervision
violently ejected. present at all times to monitor employees.
 Unexpected spinning of 3. Suitable and sufficient PPE i.e. hand gloves, mask,
hand held work pieces and mandatory PPE shall wear.
 Hand or body injuries 4. Operation to be planned to ensure maximum safety of
 Long hair and loose personnel and property.
clothing can become 5. All equipment and accessories must be marked with
entangled in moving safe working performance.
Use of various type of parts of the machine. 6. No persons are allowed to use any plant equipment
machines (Drilling  Slip, trip, fall of work without authorization of Supervisor and safety officer
22 Machines_) 4 4 16 3 1 3 Low Y
pieces 7. Equipment will be in good order & regularly
 Machine presents an maintained
electrical shock hazard 8. Great care shall be taken to protect employees from
 Closing movements harmful effects of the vapor or other impurities
between parts can lead generated on the working area.
to trapping. 9. Machines must be used accordance with
 Sharp edges or burrs on manufactures instruction.
drills, work pieces can 10. Minimize the time individuals use the equipment, i.e
cause cuts. Job rotation.
 Contact with cutting 11. Noise assessment required where deemed
fluids, oil and grease can necessary.

Title: Risk Assessment for MS for Steel Structure Fabrication for Bldg 6656 – Aircraft Shades Page(s):37 of 40
Document No.: TAB-BAH-6656-MS-SE-00053 Rev. 00 Date: 20/04/2019
Client: DUKHAN AIR BASE PROJECT Contractor:
Contract No. C-108-1

RISK ASSESSMENT
METHOD STATEMENT FOR STEEL STRUCTURE
FABRICATION FOR BLDG 6656 – AIRCRAFT SHADES

irritate skin. 12. Wear or use personal protective equipment (PPE) or

 Inadvertently starting of clothing that is appropriate for the work you are doing
the machine can present this may include, items such as safety glasses or
a hazard. goggles or face shield ( with glasses or goggles),
 Lack of space around hearing protection, dust mask, gloves, safety boots or
the machine can lead shoes or rubber boots.
operator being pushed 13. Operational manual shall be always kept in
by passers-by. equipment.
 Slippery floor surface or 14. The machine has a means of isolation, emergency
loose items around the stop.
machine can cause slip 15. A foot operated emergency stop so the machine can
that result in contact with stopped quickly in an emergency with operator not
moving parts. having to let goof the spindle feed or work piece
 Serious personal Injuries 16. A conveniently positioned mushroom headed stop
button or other suitable control device that can
quickly stop the machine in an emergency.
17. Fixed quards, or alternative interlocked guards that
enclose the drive mechanisms.
18. Handles or hand wheel to operate the table
mechanism should be set up so that they do not
rotate when the power drive is engaged.
19. There should be sufficient space around the
machine to prevent the operator from being
accidentally pushed by passers-by.
20. Do not leave a running machine unattended. Do not
leave it until it has been turned off, has stopped
running completely, and has been unplugged
21. Eye protection(goggles) worn when operating the
machine, long hair should be tied back and
protected from entanglement.
22. Loose clothing and jewellery should be tucked in
/removed.
23. Gloves or bandages should not be worn whilst
operating the machine.
24. Manual Handling tests of lifting materials and the

Title: Risk Assessment for MS for Steel Structure Fabrication for Bldg 6656 – Aircraft Shades Page(s):38 of 40
Document No.: TAB-BAH-6656-MS-SE-00053 Rev. 00 Date: 20/04/2019
Client: DUKHAN AIR BASE PROJECT Contractor:
Contract No. C-108-1

RISK ASSESSMENT
METHOD STATEMENT FOR STEEL STRUCTURE
FABRICATION FOR BLDG 6656 – AIRCRAFT SHADES

table should be reduced as can be beyond the

physical capabilities of some persons.
25. The machine should be electrically isolated before
an internal mechanism are adjusted.
26. Coolant nozzles should not be adjusted while the
machine is in operation.
27. Suitable implements should be used to removed
swarf to avoid hand contact.
28. Contact with the skin should be kept to a minimum.
Hands should be washed thoroughly after using the
machine.

Title: Risk Assessment for MS for Steel Structure Fabrication for Bldg 6656 – Aircraft Shades Page(s):39 of 40
Document No.: TAB-BAH-6656-MS-SE-00053 Rev. 00 Date: 20/04/2019
Client: DUKHAN AIR BASE PROJECT Contractor:
Contract No. C-108-1

RISK ASSESSMENT
METHOD STATEMENT FOR STEEL STRUCTURE
FABRICATION FOR BLDG 6656 – AIRCRAFT SHADES

CLASSIFICATION OF CHART

Likelihood of Risk
Likelihood Description Rating
Unlikely Occurrence close to zero 1 Classification
May Happen Capable of taking Place 2
Likely Tend or Inclined to Occur 3 1–4 Attention Required- Low Risk
5–9 Corrective Measures Required- Medium Risk
Very Likely High Inclination of Occurrence 4 10 – 16 Corrective Action Required- High Risk
Certain Most Definitely Happen‐ Not “If but When” 5 20 – 25 Elimination of Hazard - Serious Risk

Severity of Risk
Severity Description Rating Likelihood
Minor Injury First‐Aid On Site 1 1 2 3 4 5
Minor Injury Treatment Off Site 2 1 1 2 3 4 5
Up‐to‐3 days Injury Limited or no work for three days 3 2 2 4 6 8 10
Major Injury Reportable 4 Severity 3 3 6 9 12 15
Death 5 4 4 8 12 16 20
5 5 10 15 20 25

Title: Risk Assessment for MS for Steel Structure Fabrication for Bldg 6656 – Aircraft Shades Page(s):40 of 40
Document No.: TAB-BAH-6656-MS-SE-00053 Rev. 00 Date: 20/04/2019
 APPENDIX – 9.2

BSI Steel Fabrication Flowchart

 APPENDIX – 9.3

Welding Procedure
Specification (WPS)/ Procedure
Qualification Record (PQR)