PROJECT TITLE

HAWIYAH GAS PLANT (HGP) EXPANSION PROJECT SN AM PROGETTI

SAUDI ARABIA CO. LTD.

SUBCONTRACT NO. : 1210649 JOB H02755 UNIT 00

CUSTOMER: COMPANY OIL COMPANY Doc. no. H99-ZA-E-0004203
PLANT LOCATION: HAWIYAH – SAUDI ARABIA Sh 2 of 12 Rev. D

TABLE OF CONTENTS
1. SITE DESCRIPTION............................................................................................................... 3
2. SCOPE.................................................................................................................................... 3
3. REFERENCE DOCUMENTS...................................................................................................3
4. DEFINITIONS AND ABBREVIATIONS....................................................................................4
5. CONSTRUCTION CONTRACTOR DUTIES AND RESPONSIBILITIES..................................4
6. MANPOWER........................................................................................................................... 6
7. EQUIPMENTS AND TOOLS...................................................................................................7
8. PRE CAST WORKSHOP AREA PREPARATION...................................................................8
9. WORK PROCEDURE.............................................................................................................. 8
10. SAFETY REQUIREMENTS...................................................................................................11
11. ATTACHMENT...................................................................................................................... 12

This document is the property of COMPANY it must not be stored, reproduce without written authorization from the
COMPANY. PRE-CAST CONCRETE METHOD STATEMENT, H99-ZA-E-0004203 (Rev. D)
 PROJECT TITLE
HAWIYAH GAS PLANT (HGP) EXPANSION PROJECT SN AM PROGETTI
SAUDI ARABIA CO. LTD.

SUBCONTRACT NO. : 1210649 JOB H02755 UNIT 00

CUSTOMER: COMPANY OIL COMPANY Doc. no. H99-ZA-E-0004203
PLANT LOCATION: HAWIYAH – SAUDI ARABIA Sh 3 of 12 Rev. D

1. SITE DESCRIPTION
The Saudi Arabian Oil Company (Saudi ARAMCO) is the owner of the development of
HAWIYAH GAS PLANT EXPANSION Project (HGP). The project is located in the Eastern Province
of Saudi Arabia, approximately 65 km southwest of the City of Hofuf in the Al-Hasa region and
approximately 175 km southwest of Dammam. CONTRACTOR has been awarded the engineering,
procurement, construction, installation, pre-commissioning activities, commissioning & start-up
support to provide additional gas processing facilities at Hawiyah Gas Plant (HGP) to process 1070
million standard cubic feet per day (MMSCFD).
SUBCONTRACTOR has been awarded the execution of the Civil, Mechanical, Electrical,
Instrumentation and Telecom activities until Mechanical Completion

2. SCOPE
The intent of this Method Statement is to identify the required procedure in carrying out the pre-cast
items on site workshop (Preparation - Formwork - Reinforcement and embedment - Concrete
placing, curing and finishing, and installation) at HAWIYAH GAS PLANT EXPANSION Project
(HGP) in accordance with COMPANY and CONTRACTOR Specifications, Procedures and all
applicable regulatory requirements.
Reinforced concrete structures covered by this Method Statement are all foundations and U/G units
such as manholes, Catch Basins, Valve Boxes, and Lift Stations with weight not exceeding 25 ton.
D

3. REFERENCE DOCUMENTS
 SAES-Q-001 Criteria for Design and Construction of Concrete Structures
 SAES-Q-005 Concrete Foundations
 SAES-Q-012 Criteria for Design and Construction of Precast and Pre-stressed Concrete
Structures
 09-SAMSS-088 Aggregates for Concrete
 09-SAMSS-097 Ready-Mixed Concrete
 ACI 318 BUILDING CODE REQUIREMENTS FOR STRUCTURAL CONCRETE
 ACI 315 Details and Detailing of Concrete Reinforcement
 ACI 550R Design Recommendations for Precast Concrete Structures
 H99-ZA-E-0009609 Rev. B QA/QC Requirements for Construction Contractors
 H99-ZA-E-0009612 Rev. A Quality Control Specification For Civil Work
 H99-ZA-E-0004612 Rev. A Quality Control Plan for Civil Work.
 BA-617401-001 AND BA-617401-002 CONCRETE WORK GENERAL NOTES
 BA-736080-001 LEGEND AND ABREVIATIONS
 SAUDI ARAMCO Construction Safety Manual.
 H99-ZA-E-0009701 Contractor Site Safety Program
 PROJECT TITLE
HAWIYAH GAS PLANT (HGP) EXPANSION PROJECT SN AM PROGETTI
SAUDI ARABIA CO. LTD.

SUBCONTRACT NO. : 1210649 JOB H02755 UNIT 00

CUSTOMER: COMPANY OIL COMPANY Doc. no. H99-ZA-E-0004203
PLANT LOCATION: HAWIYAH – SAUDI ARABIA Sh 4 of 12 Rev. D

 H99-ZA-E-0009070 General HSE Plan

 H99-ZA-E-0009710 Project HSE Requirements
 H99-ZA-E-0009711 Project HSE Requirements for Subcontractors

4. DEFINITIONS AND ABBREVIATIONS

COMPANY : SAUDI ARABIAN OIL COMPANY (COMPANY)

CONTRACTOR /
AFFILIATED : SAIPEM S.P.A. (OOK), Snamprogetti S.A. (IK)
CONTRACTOR
Contract : the agreement entered between SAIPEM and CONSTRUCTION
CONTRACTOR for Project

CONSTRUCTION : The Petroleum Projects & Technical Consultations Co. Acting as

CONTRACTOR SUBCONTRACTOR for construction and pre-commissioning
activities.

NCR : Non-Conformity Report: Document recording a non-fulfillment of a

requirement

RFI : Request For Inspection

IFC : Issued For Construction Drawings or Document

TPTL : Third Party Testing Laboratory

5. CONSTRUCTION CONTRACTOR DUTIES AND RESPONSIBILITIES

5.1. CIVIL SUPERINTENDENT

 Overall direction ,monitoring and control all concrete works activities to the required Job
Specifications / time schedule
 Notify QC team when works are ready for inspections, as depicted in the ITPs and QCPs.
 Coordination with construction team to provide all facilities (i.e. access ways , scaffolding , etc.)
for inspection, testing and concrete placing process
 Ensure that notification time to QC is sufficient to meet notifications times to CONTRACTOR and
COMPANY, as depicted in the ITPs and QCPs.
 Provide the proper and sufficient facilities for NC clearance
5.2. QC SUPERVISOR

 Submit and verify the approval of all documents that are necessary for inspection (Material – MS
– Procedures)
 PROJECT TITLE
HAWIYAH GAS PLANT (HGP) EXPANSION PROJECT SN AM PROGETTI
SAUDI ARABIA CO. LTD.

SUBCONTRACT NO. : 1210649 JOB H02755 UNIT 00

CUSTOMER: COMPANY OIL COMPANY Doc. no. H99-ZA-E-0004203
PLANT LOCATION: HAWIYAH – SAUDI ARABIA Sh 5 of 12 Rev. D

 Ensure that all other discipline activities that must be inspected within the concrete works
construction program have been inspected and cleared.
 Organize and allocate inspection works to the Site Quality Control Inspectors.
 Coordination between TPTL and Site QC Inspector for the required testing as well as follow up
the issue of laboratory reports.
 Ensuring that all inspections are performed and recorded as per project requirements / specs.
 Coordination between CONSTRUCTION CONTRACTOR & CONTRACTOR QC teams for
solving quality issues
 Follow up the clearance of non-conformances and quality issues
 Preparation of all handing over dossiers to the other disciplines
 Review and Maintain proper document system with tracing facilities and logs for all construction
activities including IFC updated drawings , Approved Mix Designs ,MS and procedures ,
,Calibration Certificates , Material Approvals, Material Receiving , TPTL Test Reports, Third
Party Test Reports , approved R.F.I ,NCR and Quality Issues,
 Regular reporting to CONTRACTOR QC Supervisor.
 Attend the regular quality meeting with CONTRACTOR and COMPANY.
5.3. SITE QC INSPECTOR

 Verify all construction activities are completed and ready for inspection in coordination with
construction team.
 Perform / ensure that all inspections are performed in a timely manner and record as per
Specifications, ITPs and QCPs requirements.
 Ensuring that notification times to CONTRACTOR and COMPANY are upheld as per ITPs and
QCPs
 Coordination with Batch Plant QC Inspector and to ensure the correct type of concrete mix and
no concrete released from batch plant before acceptance of pre-pouring inspection by
CONTRACTOR and COMPANY.
 Coordinates with other QC Disciplines, as necessary.
 Inform CONTRACTOR/COMPANY inspectors by the official Request for Inspection, and when
their presence is required to carry out Inspections.
 Accompany CONTRACTOR/COMPANY inspectors to carry out Inspections and release
hold/witness points.
 Follow up the implementation of the corrective actions for any Non-Conformance as well as
raising any NCR to the QC Supervisor.
 Follow up concrete placing process from the start to concrete finishing and curing.
 PROJECT TITLE
HAWIYAH GAS PLANT (HGP) EXPANSION PROJECT SN AM PROGETTI
SAUDI ARABIA CO. LTD.

SUBCONTRACT NO. : 1210649 JOB H02755 UNIT 00

CUSTOMER: COMPANY OIL COMPANY Doc. no. H99-ZA-E-0004203
PLANT LOCATION: HAWIYAH – SAUDI ARABIA Sh 6 of 12 Rev. D

 Coordination with TPTL on site before and during concrete placing process for concrete
sampling.
 Coordinate with Batch Plant QC Inspector for any incidents (ie. Rejection of concrete due to
delay or unauthorized re-Tempering).
5.4. BATCH PLANT QC INSPECTOR

 Fully present in concrete batch plant during the whole pouring time with well contact facility
 Full Coordination between worksite both quality team & construction team and concrete batch
plant for ordering the correct mix ID (Class – Cement Type ) & quantities and arrival time
 Coordination between TPTL and concrete batch plant for the start of loading
 Initial check for batch plant conditions before loading the concrete
 Initial check for the fresh concrete (visual – print out check)
 Follow up concrete delivery to the pouring location
 Preparation of the daily concrete pouring log in coordination with Site QC Inspector
5.5. TPTL TECHNICIAN

 Sampling & conducting field testing according to Site QC Instructions.

 Ensuring that all necessary samples are taken and tests are carried out as required by the
Specification.
 Issuing all required Laboratory testing reports required in a timely manner
 Advice and alert CONSTRUCTION CONTRACTOR QC team for any quality problems.
5.6. HSE OFFICER/SUPERVISOR

 Ensure availability of approved work permit prior to start work.

 Ensure that personnel safety apparel PPE is worn and used.
 Ensure all persons engaged in the performance of the work are aware of and comply with
COMPANY safety regulations.
 Ensure that heavy equipment shall be installed with functional Proximity Warning Alarm System
(PWAS) and RVCCCS.
 Ensure full respect of COMPANY safety rules and regulations which shall be strictly adhered
during entire job.

6. MANPOWER
Foreman
Helper
Flagman
 PROJECT TITLE
HAWIYAH GAS PLANT (HGP) EXPANSION PROJECT SN AM PROGETTI
SAUDI ARABIA CO. LTD.

SUBCONTRACT NO. : 1210649 JOB H02755 UNIT 00

CUSTOMER: COMPANY OIL COMPANY Doc. no. H99-ZA-E-0004203
PLANT LOCATION: HAWIYAH – SAUDI ARABIA Sh 7 of 12 Rev. D

Painter
Operator (Crane,…etc)
Rigger
Safety officer
HSE Personnel
Site Supervisor
QC Inspector
Surveyor
Banks man
Carpenters
Scaffolders
Steel Fabricators / Fixers
Concrete workers / finisher
Masons
Permit Receiver

7. EQUIPMENTS AND TOOLS

Concrete Batch Plant
Concrete Pump
Concrete Truck Mixers
Air Compressor
Water tank Truck
Lifting Crane / Fork Lift
Trailer(s)
Plate / Roller Compactors
Re bars Bending M/c
Re bars Cutting M/c
Power Supply (Generator – Welding machines)
Grinding Motor
Water Stop Welding Iron
Power Mech. vibrators /Trowels / Rulers
 PROJECT TITLE
HAWIYAH GAS PLANT (HGP) EXPANSION PROJECT SN AM PROGETTI
SAUDI ARABIA CO. LTD.

SUBCONTRACT NO. : 1210649 JOB H02755 UNIT 00

CUSTOMER: COMPANY OIL COMPANY Doc. no. H99-ZA-E-0004203
PLANT LOCATION: HAWIYAH – SAUDI ARABIA Sh 8 of 12 Rev. D

Electrical saw for wood

Rigging Tools (Wires –Locks)
Carpenters hand tools (Claw Hammers - Claw Bars - Manual Saw)
Steel fixers hand tools

8. PRE CAST WORKSHOP AREA PREPARATION

8.1 Assign adequate area formwork, steel reinforcement and casting concrete as following:
 To be as near as possible from steel R.F.T fabrication ,carpentry workshop
 To be provided with ground slab with min. thickness 100mm of plain concrete
 Permanent Horizontal Platform consists of Plywood 16mm thick. Supported on wooden sec.
2"x4" rest and leveled on the concrete ground concrete slab.
 Provide adequate and proper access for workmanship , formwork materials and equipment
maneuvering (concrete pouring - loading equipment).
8.2 Provide additional area for stocking the already cast elements and cured in case that the items
will not be transported directly to the work site.
8.3 Full detailed layout for fabrication and stock area will be provided for CONTRACTOR approval.

9. WORK PROCEDURE
9.1 INITIAL VERIFICATION
 Assign the items that will be precast according to site conditions
 Estimate the concrete volume per precast element .Max. weight of the precast element will be 12
ton
 Decide according to the nature of concrete element the position of formwork (Normal – inverted –
horizontal)
 Manholes, Catch Basins, Valve Boxes, Sleepers will be cast in an inverted position. This process
allows for concrete casting one time and without joints, water stop shall be fixed when required
by design drawing.
 Foundations with pedestals but without anchor bolts or embedded plates will also be poured in
an inverted position
 Foundations that have long posts protruding concrete (such as fence foundations) will be cast in
the horizontal position. This process doesn’t need vertical fixations for such posts
 Other items such as foundation with anchor bolts shall be casted in the normal position.
 For any U/G pits or chambers it should be confirmed the correct opening (box out) size directions
from U/G arrangement drawings.
 PROJECT TITLE
HAWIYAH GAS PLANT (HGP) EXPANSION PROJECT SN AM PROGETTI
SAUDI ARABIA CO. LTD.

SUBCONTRACT NO. : 1210649 JOB H02755 UNIT 00

CUSTOMER: COMPANY OIL COMPANY Doc. no. H99-ZA-E-0004203
PLANT LOCATION: HAWIYAH – SAUDI ARABIA Sh 9 of 12 Rev. D

9.2 FORMWORK & STEEL REINFORCEMENT

 Establish the internal formwork with the internal dimensions for manholes, catch basins and
valve boxes. This formwork shall be plumbed and properly fixed.
 The internal formwork shall be strengthened with adequate struts as there is no ties protruding
the walls
 Allocate and fix the wooden frames for box out for further piping.
 If water stop will be used at the box out, divide the box out frame to 2 parts. The water stop will
be installed between these parts in such a way that half of water stop width is embedded in
concrete.
 Install and fix embedded plates (where applicable).
 Install the steel bars according to IFC drawings.
 In case of U/G pits and chambers, provide the temporary steel hooks in the middle of manhole
wall thickness.
 For the inverted items only, install steel hooks as per IFC drawings
D
 Filling and repairing the lifting hook holes with approved material non-shrink grout.
 For manholes, catch basins and valve boxes, it is preferred to keep 20 cm of the wall height
without concrete (only steel rebar are extended) for further adjustment of level at site with
surrounding finish level.
 Install additional diagonal bars as per IFC drawings at openings (box out) corners.
 Inspection of steel bars, internal formwork and opening locations as per IFC drawings (RFI
should be raised 24 hours in advance, 48 hours for Fridays or any National Vacations), the item
should be released from CONTRACTOR and COMPANY side (Hold Point of Inspection) before
the authorization to close external formwork.
 Clean the internal formwork and steel bars before closing external formwork.
 Install and fix external formwork side.
 The external formwork will be tightened using Tie rods.
 Provide the stiffeners and adjustments the verticality for the external formwork.
9.3 CONCRETE PLACEMENT
 The Pre-cast concrete grade to be 35 MPa according to SAES-Q-001.Use the maximum
allowable slump to guarantee adequate flow.
D
 Pour the concrete with relatively slow rate to maintain the stability of the element but avoid cold
joints, allow using of vibrator to ensure no honeycomb in concrete surface and good concrete
consolidation.
9.4 FORMWORK REMOVAL
 The external formwork will be removed after 24 hrs.
 PROJECT TITLE
HAWIYAH GAS PLANT (HGP) EXPANSION PROJECT SN AM PROGETTI
SAUDI ARABIA CO. LTD.

SUBCONTRACT NO. : 1210649 JOB H02755 UNIT 00

CUSTOMER: COMPANY OIL COMPANY Doc. no. H99-ZA-E-0004203
PLANT LOCATION: HAWIYAH – SAUDI ARABIA Sh 10 of 12 Rev. D

 Concrete curing to be carried out for 7 days using saturated burlaps covered with a plasticized
sheet vapor barrier, minimum 0.15 mm (6 mils) in thickness and shall be kept in contact with the
concrete surface at all times.
 De-molding when concrete exceeding the de-molding force, the pre-cast elements (casted at
D inverted position) will be put on their side to allow removal of internal formwork.
 Cut the temporary hooks only (that were used for turning the manholes) over to the cover depth
requirements by chipping and fill with the approved repair mortar as per mortar manufacturer’s
recommendation.
 Concrete finishing and coating will be after 7 days or achieving 70% of the concrete
characteristic strength-which is earlier.
 Compressive strength shall be verified according to ACI requirements, by preparing on-site cured
specimens for compressive strength, to be tested to ensure that concrete actual compressive
strength is minimum 70% of concrete characteristic strength, this may shorten the period
required for transporting the pre-cast element from concrete casting location to storing location.
 Mark the element no. and destination immediately after external formwork removal.
 Final inspection for the precast item prior to installation.
9.5 PREPARATION FOR INSTALLATION
According to SAES-Q-005, installation of precast foundations shall comply with one of the
following methods:
 A 50 mm lean concrete seal slab shall be placed in the bottom of the excavation immediately
before placing the precast concrete foundation. The precast concrete foundation shall then be
set in place prior to hardening of the lean concrete. This shall help in level adjustment.
 A layer of clean sand not more than 50 mm thick shall be placed in the bottom of the excavation.
If clean sand is used, it must be carefully leveled prior to placing the precast concrete foundation
and a 0.15 mm (6 mils) plasticized sheet vapor barrier shall be place beneath the foundation.
The foundation level shall be adjusted and checked to loading of precast element.
The coordinates of the precast items shall be located by means of strings adjusted and
intersected at the corner of the element.
Check the precast item no. and destination before directing to the site.
9.6 LIFTING, TRANSPORTING AND UNLOADING
 CONSTRUCTION CONTRACTOR will submit Lifting and rigging plan including the suitable
crane and safety precautions for CONTRACTOR/COMPANY approval.
 The lifting of the Pre-cast element will be conducted by the verified lifting points of each item
 Precast item will be lifted and transported either to stock area or directly to worksite.
 Precast items will be transported by using suitable heavy truck. They should be put in the vertical
positions and secured from falling down.
 PROJECT TITLE
HAWIYAH GAS PLANT (HGP) EXPANSION PROJECT SN AM PROGETTI
SAUDI ARABIA CO. LTD.

SUBCONTRACT NO. : 1210649 JOB H02755 UNIT 00

CUSTOMER: COMPANY OIL COMPANY Doc. no. H99-ZA-E-0004203
PLANT LOCATION: HAWIYAH – SAUDI ARABIA Sh 11 of 12 Rev. D

 Unloading of each pre-cast element will be using suitable crane as per the lifting plan / procedure
near the exact location.
9.7 FINAL INSTALLATION OF PRE-CAST ELELMENT IN SITE
 Each element to be installed in its location according to the exact elevation and orientation.
 Final Survey check for the elevation and orientation and conduct necessary adjustments.
 Close the manhole opening temporarily using wood until further piping and sealing works to
prevent soil ingress inside manholes.
 Carryout external concrete coating and backfilling as required.
 Method for surface preparation and filling the lifting lug holes with approved materials and as per
manufacturer's procedures.
9.8 INSPECTION
 RFI shall be submitted 24 hrs prior to inspection designated time (and 48 hours for weekend,
holidays and remote area locations) attached with the necessary documents (SATIP – SAIC –
IFC Drawings – Survey Report).
 SAPID, CONTRACTOR QC and SUBCONTRACTOR area QC Inspector will conduct the
inspections and tests as per stages identified in the SATIP’s.
 SATIP-Q-001-02 and its relevant checklist will be utilized according to QUALITY CONTROL
PLAN FOR CIVIL WORK, H99-ZA-E-0004612
 Particular log sheet will be established to follow up the pouring and installation of precast items.
 U/G Manholes shall be leak tested on site after installation.

10. SAFETY REQUIREMENTS

1. Only duly SA and SAIPEM approved HSE personnel shall be assigned at site.
2. All personnel shall have valid medical fitness certificate prior to working at site
3. Heavy equipment shall be installed with functional Proximity Warning Alarm System (PWAS)
and RVCCCS.
4. All work shall be as per SACSM, GI, and SAES related to safety.
5. CONSTRUCTION CONTRACTOR shall comply and shall be responsible to comply in all
respect with COMPANY safety rules and regulations which shall be strictly adhered during
entire project duration.
6. CONSTRUCTION CONTRACTOR shall provide and maintain all temporary lights, guards and
warning sign tapes when and where necessary for protection of construction staff and
equipment.
7. All vehicles & equipment used shall be equipped with fire extinguisher of suitable capacity and
reverse alarm.
8. CONSTRUCTION CONTRACTOR shall provide and maintain sufficient and adequate first aid
equipment at the site to ensure that a sufficient number of personnel are trained in the
performance of first aid techniques.
 PROJECT TITLE
HAWIYAH GAS PLANT (HGP) EXPANSION PROJECT SN AM PROGETTI
SAUDI ARABIA CO. LTD.

SUBCONTRACT NO. : 1210649 JOB H02755 UNIT 00

CUSTOMER: COMPANY OIL COMPANY Doc. no. H99-ZA-E-0004203
PLANT LOCATION: HAWIYAH – SAUDI ARABIA Sh 12 of 12 Rev. D

9. CONSTRUCTION CONTRACTOR shall be responsible for ensuring that personnel safety

apparel PPE, (Protective clothing, hard hats, safety shoes, masks) is worn and used.
10. All equipment for use in the performance of the work shall be in a safe and proper condition and
capable of performing the intended work.
11. All persons engaged in the performance of the work are aware of and comply with COMPANY
safety regulations.
12. The necessary precautions shall be taken to prevent damage to the project site and to property
and the environment adjoining the worksite and to keep it clean, tidy in good order at all times.
13. CONSTRUCTION CONTRACTOR shall confine its operations strictly with the limits of the
working strip.
14. Existing cables, P/L and other underground facilities or services if indicated on the drawings
shall be detected, located and exposed by cable detector, hand excavation; proper notification
shall be given in advance of excavation.
15. CONSTRUCTION CONTRACTOR shall utmost take care to mark all exposed underground
facilities or services and to avoid any damage to surfaced roads and other above ground
facilities.
16. Underground facilities or services shall not be moved or disturbed without specific agreement in
writing from COMPANY representative.
17. The sides of trenches excavated in week soil to be safely sloped shoring benching etc.
18. Work permit will be received by an approved work permit receiver prior to start of any activity.
19. All heavy equipment operations shall have both SAG license and SA Certificates according to
GI 7.025.
20. All lowering activities that require road closures will be in accordance with GI-1021.00.

11. ATTACHMENT
Lifting hook calculation
Appendix A – Job Safety Analysis