Method Statement- HOT WORKS (GRINDING - WELDING)

METHOD STATEMENT
FOR HOT WORKS (GRINDING - WELDING)

BMS HQ DESIGN
IPIC TOWER, ABU DHABI, UNITED ARAB EMIRATES

Client: MDC BUSINESS MANAGEMENT SERVICES LLC

Consult. : FOCUS INTERNATIONAL ENGG. CONSULTANCY LLC
Main Cont.: CENTRIC INTERIORS
MEP Cont.: TESTER ELECTROMECHANICAL
----------------------------

Method Statement and Risk Assessment for Hot works (Grinding - welding)

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 Method Statement- HOT WORKS (GRINDING - WELDING)

1. Scope

This Method Statement provides the Control Sequence and methodology that will be used during the installation of Chilled water piping at BMS HQ project at IPIC tower. The Method Statement
would include a Risk Assessment for each activity which lists out potential risks involved and risk mitigation techniques for each activity. The method statement would help establish safety
standards, activity guidelines, and define roles and responsibilities.

2. Reference

 Contract documents
 Approved shop drawings and material approvals

3. Definitions and abbreviations

The following abbreviations would be made use of in this document

 Client – MDC Business Management Services LLC

 Consultant – Focus international

 Contractor – Centric Interiors

 PM - Main Contractor Project Manager

 PE - Main Contractor Project Engineer

 SE - Site Engineer

 SI - Main Contractor Safety Inspector

 SF - Main Contractor Section Foreman

 PQP – Project Quality plan

 ITP - Inspection and Test Plan

 MS - Method Statement

 RA - Risk Assessment

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 Method Statement- HOT WORKS (GRINDING - WELDING)

 MIR - Material Inspection Request

 WIR - Work Inspection Request

 NCR - Non Conformance Report

 QA/QC–Quality assurance/Quality control

 HSE - Health safety and Environment

 PPE – Persona protective Equipment

 TBT - Toolbox talk

 MSDS-Material safety data sheet

 COSHH- Control of substance hazardous to health

 NIOSH- National Institute for Occupational Safety & Health

4. Roles and responsibilities

 Project manager (PM)

The PM will have the overall responsibility of the project for execution, Quality, Health safety and Environment. He shall maintain the planning progress and co-ordination of works.

 Site engineer (SE)

- To ensure that the works are carried out according to the Contract Specifications and approved method statement.
- To provide all necessary information and distribute responsibilities to his construction team.
- To monitor the progress of work in relation with the work program and to report to the construction manager.
- To co-ordinate with the safety officer and to ensure that the works are carried out in safe practicing methods.
- To ensure that the foreman is fully aware of the work sequences and related testing frequencies before proceeding with the installation.
- To ensure compliance of the works with the related approved quality procedures
- Report to PM in daily basis on site progress.

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 Method Statement- HOT WORKS (GRINDING - WELDING)

 Supervisor/Charge hand

Supervisor/Charge hand will be directly responsible for the day-to-day job at site, for coordinating of work with skilled and unskilled labor or any other staff assigned in his area

 Safety Inspector

- To ensure sound implementation of all safety procedures and measures related to the nature of works being carried out, in accordance with the HSE Plan and general safety rules.
- To ensure that all persons involved in the work are aware of their responsibilities, and having enough understanding of the related safety procedures.
- To report to the Project Manager and to coordinate with Construction Manager in order to ensure that all the implemented and adopted safety measures are effective enough to
maintain safe working atmosphere in the site.
- To ensure that all safety statistics are recorded and reported to the project manager.
- To maintain continuous inspections of the site activities, advise and train the involved persons on daily basis to prevent accidents, personnel injury and property damage.
- To give special concern to housekeeping, and ensure that the site is maintained clean and tidy.
5. Contractor contact details

Name Organization Mobile Email

Tester Electromechanical
Sunil Kumar +971 558033014 [email protected]
LLC
Tester Electromechanical
Shoji Joseph +971 526921079 [email protected]
LLC
Tester
Mohamed Dab +971 525138452 [email protected]
Electromechanical LLC

6. Storage
- All flammable items to be stored separately and adequate protection to be provided.
- Adequate fire extinguishers to be provided.
- Cylinder to be kept up right and secured
- Equipment’s shall be operated by trained personals.

Personal Protective Equipment:

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 Method Statement- HOT WORKS (GRINDING - WELDING)

 Helmets

 Safety Shoes

 Masks

 Hand Gloves

 Cover all

7. Method of operation

Hot work task identification

 Welding
 Grinding

Hot work hazard identification

The Workplace Manager and/or Management SE in consultation with employees and HSR are to identify and record hazards (e.g. fire and explosion) associated with the hot work tasks to be undertaken, in
the ‘Hazard Description’ column of the OHS Risk Register.

Record hot work risk controls

The Workplace Manager and/or Management SE in consultation with employees and HSR are to identify, implement and record risk controls to manage hot work tasks in the OHS Risk Register, using the
Hierarchy of controls. Examples include:

 Elimination – use pre-cast components e.g. purchase materials already joined.

 Substitution – conduct arc welding instead of flux-cored wire welding to reduce the risk of exposure to radiation and fumes

 Engineering – install local extraction ventilation systems, isolation of ignition sources, and installation of welding bay screens

 Administration – develop and provide training in Safe Work Procedures for employees

 Personal Protective Equipment (PPE) – spark/fire resistant clothing or welding masks

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 Method Statement- HOT WORKS (GRINDING - WELDING)

Isolation of ignition sources.

The Workplace Manager and/or SE are to ensure that all hazardous areas/items surrounding the hot work area are isolated or otherwise controlled. This may include removing flammable materials and
cordoning/screening off the area to prevent the ignition of any materials, contaminants, agents, or conditions that may be harmful to persons undertaking the tasks and others or property.

Fire watch personal.

The Workplace Manager and/or SE, or Contractor is to ensure that a trained fire watch observer is appointed and present for the entire duration of the hot work task. The fire-watch observer must be able to
operate fire and emergency equipment and wear PPE (e.g. welding mask).

8. Man Power Requirement

Manpower requirement like Project Engineer, Supervisor/ Foreman, Skilled operatives and unskilled labor depends upon the approved construction program and site progress.

9. House Keeping
All work places where any site operatives are working will be cleaned from scrap materials derived from their work, ensuring clean and healthy work environment as well as to maintain free
access and egress in the event of an emergency. Waste removal will happen in two stages.

 Refer to waste management details.

10. Control of Health Hazards

Implementation of Health & Safety procedures and checks shall be done as per contract agreement and the approved site HSE plan. The safety officer shall carryout the necessary routine
inspections.

 Risk Controls: Risk assessment and their controls are carried out for each activity and enclosed within the detailed section. Each Risk assessment is attached along with their corresponding
detailed method statements.
 All personnel should comply with site HSE Plan.

 All personnel should comply with corresponding Risk Assessments.

 Adequate HSE control measures should be provided as required in the Risk Assessments.
 All personnel should attend Site Safety Induction.

Every site operative must use the required job specific PPE

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 Method Statement- HOT WORKS (GRINDING - WELDING)

11. Training
Tradesmen performing the any activity will be experienced technicians. If deemed necessary specific team/Individuals will undergo further training and awareness programs for this activity
by the Project/QA-QC Departments. Toolbox talks will provide general training and awareness for each activity and also in health & safety matters and precautions

12. QA / QC Documentation
QA/QC forms shall be used to verify and maintain quality throughout the project as per the approved Project Quality Plan. Checklist and ITP would be used to ensure that all activities are
carried out as per contract requirements and approved method statement.

13. Distribution
 Client

 PM/CM

 Consultant

 Safety inspector

 QA/QC

14. Attachment
 Risk Assessment – HOT WORKS (GRINDING - WELDING)

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 Method Statement- HOT WORKS (GRINDING - WELDING)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

LIKELIHOOD

LIKELIHOOD

LIKELIHOOD
RISK LEVEL

RISK LEVEL

RISK LEVEL
SEVERITY

SEVERITY

SEVERITY
(N
S. IDENTIFIED HAZARDS WITH ADDITIONAL
ACTIVITY or EXISTING CONTROLS
No EFFECTS CONTROLS
R)
Action
L S R1 L S R2 L S R3
By:
 Check the casing for any damages, missing screws and cracks.

 Check the plug and lead wire for damage; make sure the current test tag is
attached.

 Make sure all controls operate properly.

 Inspect the disc for uneven or excessive wear, damage or cracks.

 Check if the disc being used is suitable for the work. (Note - an angle grinder
must not use fiber cut off wheels).
 Electric Shock
1. Pre-start
01 R 3 5 15  The guard must be fitted tightly and should not be loose. 1 5 5 SE/SI 1 5 5
Checks
 Flying objects
 All grips and handles must be fitted securely and should not be loose.

 If you locate any damage, out of test or missing parts, arrange for repairs
straightaway - DO NOT USE THE MACHINE.

 Replace the inappropriate or the faulty disc with the right disc suited to the task
and the machine. (Refer below)

 NEVER EVER use a machine without suitable guards.

02 2. Replacing R  Moving parts 3 3 9 • Before starting on maintenance, unplug the machine. 1 3 3 SE/SI 1 3 3
Discs

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 Method Statement- HOT WORKS (GRINDING - WELDING)

• For carrying out any maintenance, the machine must always

be placed on a stable and firm surface such as a bench.

• Loosen the spindle nut using the correct tools / spanners

supplied.

• Clean the backing plate, spindle and guard using a brush.

• Check the backing plate is able to sit flush and the spindle
thread is undamaged.

• Ensure the replacement disc is compatible, is of the right type

for grinding the material, has the proper matching speed, the
 Cuts and/or abrasion injury to hand right hole diameter for the spindle, and the right outer
diameter.
 Foreign body in eye
• After mounting the disc, washers and nut in the proper order,
use the right tools/spanners to tighten firmly.

• Whenever handling sharp or rough parts, protect your hands

by wearing leather gloves.

• When cleaning with compressed air wear eye protection.

• Never use a disc which is incompatible, or does not meet the

requirements listed in the left column.

• Ensure all surfaces are clean.

• The nut must never be over tightened.

03 Operation R • Flying particles 3 4 12 • Always grind in a manner that directs the sparks away from 1 4 4 SE/SI 1 4 4
your body.
• Foreign body in eye
• Never direct the sparks towards another person.
• Noise
• Wear eye protection to avoid getting debris and dust in the
• Dust eye.

• Vibration • Use additional protection to eyes and face when working in

restricted areas where the sparks can get reflected back

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 Method Statement- HOT WORKS (GRINDING - WELDING)

towards the user.

• Loud noise can be a hazard, especially in restricted or

closed areas.

• Provide adequate ventilation for areas where grinding of

rusted surfaces or previously painted surfaces, and where
dust may be generated because of the process of grinding.

• Grinding of uneven surfaces may cause the grinder to

move or vibrate in hands.

• For excessive vibration, switch off the grinder and check

the disc for signs of damage.

• Always use protective clothing such as trousers, long

sleeves, overalls and apron.

• Advisable to use safety goggles.

• Use face shield together with other eye protections.

• It is essential to wear hearing protection.

• It is essential to wear a respirator or a suitable mask to filter

particulate dust.

• Gauntlets or heavy gloves can be used to reduce the

effects of vibration.
04 Work at height R  Fall from height resulting to injuries and property 3 5 15 Ladders: - 1 5 5 SE/SI 1 5 5
(Use of ladders; damage • Ladder shall be inspected before use.
scaffolds) • No overloading, observe load rated capacity of the ladder.
• Top two rungs of the ladder shall be kept free.
• A watchman shall hold the ladder from bottom
• Observe 3 point contact rule while ascending / descending the ladder.
• Maintain safe distance from folding parts of ladder.
• Use hand gloves, be aware of various pinch points.

Scaffolds: -
• Only competent scaffolders are allowed to erect and dismantle the

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 Method Statement- HOT WORKS (GRINDING - WELDING)

scaffolds.
• Scaffolds must be inspected and tagged by a competent inspector prior
to start the work.
• Inspection tags must be reviewed weekly. Visual checks to be done
daily.
• Always ensure that the manufacturer instructions and legal requirements
are followed while erecting, working and dismantling the scaffolds.
• Do not move the scaffolds with men and materials on the platform.
• Ensure the ground is stable and free of obstruction and potential for trip
hazards.
• Ensure the platform kept clean and tidy always.
• Do not climb through beams, use access ladders instead.
• Do not throw materials to and from the scaffolds.
• Do not remove the scaffold components; if you are not trained or
permitted to do so.
• Operative must be trained on safe working on scaffolds.
• Competent supervision is mandatory though out the works.
• Full body harness must be used over 6m heights and it must be secured
to safe anchorage.
05 Use of Power Tools R • Injures from use of power tools or by 3 5 15 • Power tools to be in good working condition with inspection tag and 1 5 5 SE/SI 1 4 4
(hammer drill, incompetent personnel color coded.
angle grinder, • Only tools of approved standard will be used
• Entanglement from moving / rotating parts
power drill, tighter • Damaged/defective tools to be taken out of service immediately.
machine, etc.) • Hand and arm vibration syndrome
• Power tools should be double insulated. Safety guard should be fixed
• Inhalation of dust properly in rotating parts.
• Tripping from trailing leads • Only authorized and competent personnel should use the power tools.
• Electrocutions / burns from faulty electrical • Isolate the work area with warning tapes and sings.
equipment • Loose clothing, jewelry and long hair to be kept clear of moving
• Fire due to use of substandard tools parts
• Select tools with lowest vibration levels.
• Ensure adequate ventilation in the working area. Wear dust masks.
Wash hands thoroughly after producing dust.
• Keep the lead wires off the ground and if not possible then make sure
the lead wires will not cause a tripping hazard.
• Ensure an adequate power supply through isolating devices in the
Distribution Boards.
• Use only industrial sockets for making the connections.
• Switch off the power tools & unplug the socket when not in use

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 Method Statement- HOT WORKS (GRINDING - WELDING)

• Provide sufficient information and instructions to the operator prior

to start of work.
• Electrical cables and fitting in good working condition and of an
approved type.
• ELCB to be provided to electrical power supply.
• Qualified person to test all portable electrical hand tools before use
• Adequate numbers of fire extinguishers to be strategically positioned
in the area.
• Emergency escape routes to be clearly marked and communicated to
all workers.
R • Housekeeping crew must be competent.
• Ensure a safe access and egress to the work area.
• Materials to be stored in location approved by main cont. or client
• Tools/equipment to be stored in lockable toolbox
• Wet/damp sweeping techniques to be used for general cleaning to
control dust levels.
Housekeeping • Waste materials shall keep in designated bins.
• General • All the scrap materials shall be separated properly and stacked safely.
work area • Waste management procedure shall be followed as mentioned in the
cleaning Slip and trip, inhalation of dust, foot injury from approved HSE Plan.
06 • Storage of 3 3 9 1 3 3 SE/SI 1 3 3
unattended materials • Regular cleaning (throughout the work and before and after of each
materials
shift) and removal of wastes and scrap materials from the work area to
• Storage of
the designated collection points and storages in order to create a safe
tools/equipm
working environment.
ent
• Responsible engineer must ensure the work area is safe prior to
deployment and instruction to work.
• Provide adequate instructions for the safe use and maintenance of
PPE, safe manual handling and ensures prompt compliance during the
housekeeping works with adequate supervision.
• Provide appropriate hand gloves, respiratory protection, overalls and
other personnel protective equipment to the workers.
07 Oxy cutting / Burns from oxy/acetylene tools • All work conducted by qualified and competent personnel
grinder cutting Eye injuries whilst grinding and buffing • Flashback arresters must be fitted to oxy/acetylene sets at both ends.
Grinder disc shattering
Noise from grinder • Hot works permit to be completed, signed off & onsite in work area
Flash back on the oxy/acetylene set fire during activities
• Wear the appropriate PPE for oxy cutting the ends off pipes

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Method Statement- HOT WORKS (GRINDING - WELDING)

including gloves and oxy goggles. Apron & Spats Wear the appropriate
PPE for grinding and buffing pipe including double eye protection
(protective glasses and face shield of grinding/cutting type not welding
or acetylene cutting) and hearing protection
• Do not wear hi-visibility vests. Hi-visibility vests are highly
flammable and may melt onto skin
• Cotton drill clothing to be worn
• Ensure appropriate guards are fitted to grinders and grinding discs
are correctly applied to the grinder. If unsure of the correct application of
the grinding disc ask a supervisor or leading hand to demonstrate and
verify the correct method of application
• Ensure that grinding and buffing equipment are unplugged from the
power source when changing discs or buffs
• Burns & first aid kit to be onsite. Report any incident or accident
immediately
• Ensure fire blanket & adequate size firefighting equipment is readily
available
• Ensure flammable items & work area is clear to prevent fire
• watch person must be appointed and must be equipped with fire
extinguishing equipment

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