Method Statement for Steel Structure Man Basket Fabrication and Usage

Aktogay Copper Project Sulphide Plant

Method Statement for Steel Structure Man

Basket Fabrication and Usage

11250-ZB-NFC-0000-MS-S-0083

C 12-Dec-2015 B 01-Dec-2015 A 08-Jun-2015 Rev# Date Re-Issued for Yang Dezhuang Review/Comment Re-Issued for Yang Dezhuang Review/Comment Issued for Yang Dezhuang Review/Comment Reason for Issue Prepared by Liu Baoguo Guan Chengming Ge Wanjia Chen Shehua Reviewed by Guan Chengming Sun Yuanpeng Approved by

Method Statement for Steel Structure Man Basket Fabrication and Usage 11250-ZB-NFC-0000-MS-S-0083 Rev. C

Table of Contents

Ⅰ. General Situation ......................................................................................................................... 3

1.1 General Situation ................................................................................................................. 3 1.2 Technical Preparation .......................................................................................................... 3 1.3 Men Basket Designed Diagram........................................................................................... 4 1.4 It is Mandatory the Following Requirements: ..................................................................... 6 Ⅱ. Certificate of PLM-2 Man Basket ............................................................................................... 6

2.1 General Date ....................................................................................................................... 6 2.2 .Regulation for Fabrication; Operation and Maintenance ................................................... 6 2.3 Properties and Main Data Sheet .......................................................................................... 7 2.4 Rules of Operation .............................................................................................................. 7 2.5 Inspection ............................................................................................................................ 8 2.6 Transport and Storage ......................................................................................................... 9 2.7 Acceptance Certificates ....................................................................................................... 9 Ⅲ. Man Basket Calculation .............................................................................................................. 9

3.1 Materials and Dimensions ................................................................................................... 9 3.2 Wind load Formula:............................................................................................................. 9 3.3 Welding Allowable Stress ................................................................................................. 10 3.4 Tensile and Flexural Stress Account.................................................................................. 10 3.5 Welder and Equipment Information .................................................................................. 11 IV. Risk Assessment ........................................................................................................................ 12

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Method Statement for Steel Structure Man Basket Fabrication and Usage 11250-ZB-NFC-0000-MS-S-0083 Rev. C

Ⅰ. General Situation

1.1 General Situation

This project is the statement for steel structure man basket use. We have already gotten the certification of man basket from local government. And the man basket meet the standard of the GOST 27372-87. 1.2 Technical Preparation

After making a self-inspection and joint inspection to the steel structure construction drawing, organize the construction team, crane driver, rigger, lifting worker, man basket installation worker to be familiar with the construction process and relevant technical requirement, and display a complete technical disclosure, to be clear with the installation quality and safety requirement.

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Method Statement for Steel Structure Man Basket Fabrication and Usage 11250-ZB-NFC-0000-MS-S-0083 Rev. C

1.3 Men Basket Designed Diagram

Diagram of man basket

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Method Statement for Steel Structure Man Basket Fabrication and Usage 11250-ZB-NFC-0000-MS-S-0083 Rev. C

Top of man basket Bottom of man basket

Diagram of lifting lug

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Method Statement for Steel Structure Man Basket Fabrication and Usage 11250-ZB-NFC-0000-MS-S-0083 Rev. C

1.4 It is Mandatory the Following Requirements:

1) Crane operators must have certification for the type of crane that is using.

2) Riggers must be certified for an creditable company. 3) Slings and shackles must have certification. 4) Works must be trained for the use of man basket.

5) Use one more sling at the middle of the man basket. This is for a safety condition.

6) All the personnel must have harness (100%) all times.

Ⅱ. Certificate of PLM-2 Man Basket

2.1 General Date

The man basket used for moving the erectors, tools and materials and for execution of work at height. The man basket can be used for construction, renovation and repair of buildings and structures. Moving the man basket is carried by cranes. 1) Manufacturer: Huang Yanbing 2) Date of fabrication:

3) Permissible temperature range of operation:-30℃~ + 45°C 4) Permissive wind velocity is 11m/s

2.2 .Regulation for Fabrication; Operation and Maintenance 1) Steel structure rules of production and acceptance of work 2) Occupational safety and heals protection in construction industry 3) The rules of the safety operation of the cranes in RK 4) Different types of scaffolding, general specifications 5) Fabric slings, requirement for design and safe operation

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Method Statement for Steel Structure Man Basket Fabrication and Usage 11250-ZB-NFC-0000-MS-S-0083 Rev. C

2.3 Properties and Main Data Sheet 1) Dead weight: 219.kg 2) Maximum load capacity: 300kg 3) Capacity: 2 persons

4) Main dimensions: 1.5m (Length)*0.884m (Width)*1.88m (Height)

5) The man basket is welded structure from rolled profiles, the frame and fencing of the man basket is fabricated from steel pipe and steel rebar. The bottom of the man basket is fabricated from rippled decking, side strips of sheet steel. 2.4 Rules of Operation

1) Secure slings the man basket to the hook lifting device by 4th slings-“CTP 2”（or “USC 2-2.0”),by hanging loop of slings on the one hand directly on the hook of crane, and from other side need to connect the loops of sling to the lifting hugs of man basket using shackles. When using a sling type 1 USC-hooks of the slings directly connect to the lifting lugs of man basket. Shackle 4 pieces of wire rope certified which wire rope safety factor is equal or greater than 12.

2) The uploading of the materials, and tools need to carry out by way which exclude their downfall out of the man basket while working. Never load piece goods (Such as bolts) in bulk. Measures should be taken to exclude the possibility of falling materials or tools above the on board band.

3) In the same into the man basket can locate not more than two erectors. Thus the total weight of the erectors, materials and tools must not exceed the maximum loading capacity of the man basket. Erectors into the man basket have to connect the lanyards of their harness tethers to an additional sling which hang directly on the hook crane. 4) Before lifting the door must be closed for locking device.

5) In the process of lifting the man basket should be fixed from the ground against rocking by rope.

6) The commands to crane operators may be filled as signals (with sufficient

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Method Statement for Steel Structure Man Basket Fabrication and Usage 11250-ZB-NFC-0000-MS-S-0083 Rev. C

visibility), or by the radio. 7）Basket door must swing inward.

8）Total load weight less than 50% crane rated capacity.

9）Add wire mesh between toe board and handrail, as well as the top of basket to prevent from falling objects.

10）JHA permit to work as required prior to each use.

11）Supervisor and rigger must do a visual inspection of the man basket before using. 12）Use of man basket needs a hazard analysis and a work permit.

13）Use a 5th sling with the capacity to support all load, and the middle of the man basket. 2.5 Inspection

1) During acceptance into operation, a visual inspection of metal and welded joints should be carried for the pressure of unacceptable defects. The man basket, which passes a visual inspection, exposed the static test. 2) PT testing

All finished man basket welding should pass the PT test, and be with qualified RT test before putting into use.

3) Static test are carried out by load which exceeding loads capacity of man basket by 50% of 300kgs.(The load evenly distributed on the flooring of man basket), then the man basket with counter cargo lift off the ground by crane for 10 minutes. The member of the fencing must bear a load of at least 70kgs applied to the top handrail in a direction perpendicular to its axis, alternately in the horizontal and vertical planes. Static test of man basket carried out periodically, at once a year.

The man basket should have the date containing the following information: a) Symbol b) Load capacity c) Date of fabrication

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Method Statement for Steel Structure Man Basket Fabrication and Usage 11250-ZB-NFC-0000-MS-S-0083 Rev. C

d) Date of latest test e) Date of next test f) Man basket weight 2.6 Transport and Storage

1) The transportation of the man basket can make any kind of transport, ensuring of its safety from damage.

2) Do not drop the man basket when unloading, do not move portage, and do not perform other action resulting in damage to structural of man basket. 3）Store only on the backing, to exclude contact with the ground. 2.7 Acceptance Certificates

1) The man basket is made in acceptance with the drawing and complies with GOST. 2) The result of the test of man basket found fit for use.

Ⅲ. Man Basket Calculation

3.1 Materials and Dimensions

1）Main dimensions:2m (Length)*0.7m(width)*1.2m(Height) 2) Material for the man basket:

Round steelφ8：L=16.2m Steel panel δ=5mm，S=2.21m2 Steel pipe φ48*3.5：L=33m

3) Weight T=16.2*0.395+5*2.21*7.85+33*3.841=219.kg 4) Weight calculation:

Total weight of man basket=Dead weight+ load capacity + weight of tools=219.+100*2+20=439.kg 3.2 Wind load Formula:

Qwk =Wk*F (See item 5.1.4 in JGJ202-2010)

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Method Statement for Steel Structure Man Basket Fabrication and Usage 11250-ZB-NFC-0000-MS-S-0083 Rev. C

Qwk: Standard wind load of man basket (KN) Wk: Standard wind load (KN/㎡) F: Force area

Standard wind load formula: Wk=BgzUsUzW0 (see item7.1.1-2 in GB50009-2001) (The maximum operation height of man basket is 50m, wind area of man basket is 0.5 ㎡, and wind area of other equipment is 2 ㎡) Bgz-Gust factor at height of Z (1.54) Us-Wind load size factor (0.6)

Uz-Wind pressure elevation variation factor (2.03) W0-Gust factor at height of Z (Maximum factor value 0.9) Wk=1.54*0.6*2.03*0.9=1.69KN/m2

Qwk=Wk*F=1.69*2.5=4.225KN, thus m=431.12kg Maximum operation loads: 439. kg+431.12kg≈871kg 3.3 Welding Allowable Stress σk= F/∑Ak≤σem σk: Welding stress

F: Maximum operation loads

σem: Welding allowable stress(S235JR material: 1250kgf/cm2) Welding area account formula: Ak=2*lk*a F=871kg，t=6mm=0.6cm，lk=10cm 0.3≤a≤0.7t→0.3≤a≤0.7*0.6(a=0.3)

Thus σk=F/∑Ak=871*9.8/4* (2*10*0.3)=355.658kgf/cm2≤1250kgf/cm2 Welding stress of lugs of man basket reaches the requirement. 3.4 Tensile and Flexural Stress Account σt=Fy/A，σf=Mx/Weg

σt=Fy/A=871*9.8/2*4*1*4=266.74kgf/cm2

σf=Mx/Weg=871*9.8/ (1*5.62/6)*4=266.74kgf/cm2

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Method Statement for Steel Structure Man Basket Fabrication and Usage 11250-ZB-NFC-0000-MS-S-0083 Rev. C

∑σ=σt+σf=266.74+266.74≤1600kgf/cm2

Tensile and flexural stress of lugs of man basket reaches the requirement. 3.5 Welder and Equipment Information Welder name: Huang Yanbing Work experience: 18 years Welding type: Electric arc welding

Electrode type: Basic electrode AS B-204 EN ISO 2560-A：E 46 4 B 32 H10

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Method Statement for Steel Structure Man Basket Fabrication and Usage 11250-ZB-NFC-0000-MS-S-0083 Rev. C

IV. Risk Assessment

Conclusion Hazard Analysis Reduce risk measures Remaining hazard analysis Likely Consequence NO. Identified Risk Risk score Risk score Control Measures Related people Result Result Rate Rate When No safety 1 measures, no training, no certificates Accidents Less supervision, no supervisor handling not timely, enlarge the accident Mechanical 3 equipment defects Aerial work doesn’t take measures of protection, 4 operating workers do not wear safety harness as per regulations Falling injury machine injury, human injury 3 4 7 2 6 8 Incidents and injury 3 5 8 Prepare well with safety measurements, strictly comply with rule No training, no operation Supervisor and operator operation Before 1 1 2 Arrange supervisor with high responsibility and lots of experience, leaving duty during operation process in not permitted Equipment maintaining reinforcement, changing, accessories changing and inspection by repairing personnel to ensure the safety and come into use Supervisor and operator Operating 2 1 2 3 Supervisor and operator Operating Operating 2 1 3 3 5 8 Wearing safety harness as per regulations when doing the aerial work Supervisor and operator 2 1 3 Page 12 of 16

The sling doesn’t tie above from the center of 5 gravity without any security measures due to the exceptional cases The unacquaintance of the hoisting plan, hoisting equipment, 6 hoisting operation regulation, commanding signal and security acquirements. Material Swinging dropping, 7 machine leaning lead to serious accident and or Method Statement for Steel Structure Man Basket Fabrication and Usage 11250-ZB-NFC-0000-MS-S-0083 Rev. C

The sling must tie above from the center of Hoisting accident gravity. In the specific case that ties below 2 6 8 the center of gravity, safety measures shall be taken with trained and qualified hoisting workers Supervisor and operator Operating 1 2 3 The operator or the worker must be Hoisting accident familiar with the hoisting plan, hoisting 3 6 9 equipment, hoisting operation regulation, commanding signal and security acquirements. Supervisor and operator Operating 2 1 3 Lead to accident and cause casualties 3 5 8 Check before working every day. Before operating Supervisor and operator 1 1 2 cause casualties. Page 13 of 16

Method Statement for Steel Structure Man Basket Fabrication and Usage 11250-ZB-NFC-0000-MS-S-0083 Rev. C

1. The inspection before working shall be taken as well when the operators shift their works. 2. Check and run the alarm devices. 3. Report the damages and faults. 4. Report the fault that may affect the The abnormal 8 maintenance of machines security to the director. Hoisting accident 2 6 8 5. The devices shall be clear of the site before informing of the HSE manager after correction of the faults. 6. Maintain and repair the equipment according to the requirements of the manufacture. 7. The operator must read the relevant chapter of the operation and maintenance manual. Supervisor and operator Operating 1 2 3 Page 14 of 16

Method Statement for Steel Structure Man Basket Fabrication and Usage 11250-ZB-NFC-0000-MS-S-0083 Rev. C

1. Chains, riggings and other accessories shall be qualified and marked with their safe working load/max working capacities. 2. Chains, riggings and other accessories shall be tested by professionals and clipped with stickers. 3. The rigging charger or operator must check the status of the equipment including stretching of the chain units, surface abrading and cuts on the rigging. 4. Different types of hoisting sling which The absence of inspection of 9 devices. The irregular operation. Equipment damage, causing casualties 3 4 7 only can be connected with snap ring. 5. Only when the hoisting weight equal or over the original load weight, the hoisting sling(including different types of hoisting sling)can be connected to put in use. 6. The snap ring is needed when the sling bolts approach to the ring bolts or lifting eye. 7. All the lifting hooks should have insurance lock devices to avoid the movement of the hoisting objects. 8. When using many strand of hoisting sling, all need fix on the hoisting hooks. 9. The damaged cloth hoisting sling should be checked and be qualified and only can be used when attach tag. 1. Rigger should have the special type Lifting 10 construction method is incorrect certification before operation, and make Falling objects from high attitude 2 4 6 lifting method statement for every lifting object. 2. Lifting method statement would be decided by appearance, size and weight of object. Supervisor and operator Operating Supervisor and operator Operating 2 1 3 2 1 3 Page 15 of 16

Method Statement for Steel Structure Man Basket Fabrication and Usage 11250-ZB-NFC-0000-MS-S-0083 Rev. C

1. If the lifting weight is not sure, people should consulate other people instead of guess. 2. Load weight and reaching radium should also refer to load diagram. 3. The lifting object cannot over load according to the load diagram. 4. The load diagram should be kept in operation cable. 5. People should make lifting plan if the object over 40t or over 70% of load capacity. Falling Without consider 11 the lifting limitation objects from high attitude, people injured 2 5 7 6. Lifting sling should be set on the plain surface, rather than the sharp edge. 7. Other people who do not deal with the lifting work cannot enter the lifting area. 8. Hawser cable should be longer than 16mm and made by nature fiber or similar rope. It can control the swing of lifting object when necessary. 9. Long lifting object (over 12m) should have 2 hawser cable and 2 people take responsibility. 10 Ensure the balance of lifting object. 11. Ensure that there is no component slide of falling from the object when lifting. 12. People cannot stand down the lifting object or other barriers. 13. People should manage the object when lifting and the object cannot lift over people. Drive against 12 regulation after hoisting operation. No personnel 13 allowed to enter the hoisting area. Personnel injury 2 4 6 1. Lifting cargo should press close to the ground when hoisting. 2. Cable rope controller should give signals to operator when hoist and lay down the cargo. Personnel injury All people are not allowed to enter the 2 5 7 restricted area before the hoisting cargo down to 300mm above ground. Supervisor and operator Operating Supervisor and operator Operating Supervisor and operator Operating 1 1 2 2 1 3 1 1 2

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