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Method of Statement
Farakka Line-II Expansion Project

ASSEMBLY OF RING BEAM, ROOF STRUCTURE,

PENTHOUSE
AND
ERECTION OF STRUCTURES AND EQUIPMENT
ERECTION PROCEDURE

Prepared By Reviewed Approved BY

LNVT ACL ACL

Mr. Sreekanth Ramineni

[Prepared By] [Checked By] [Approved By]

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Introduction:
The Farakka project involves the erection of a clinker silo roof with a total weight of 220
tons. The roof structure will be assembled at ground level, comprising 18 rafters, 90 tie
beams, 120 bracing, and 287 purlins. The primary purpose of this assembly method is
to minimize erection time and significantly reduce the risk associated with working at
heights.
This innovative approach to major erection will be implemented for the first time in
ACC, Ambuja, and Adani projects (AAA)

Below is the figure showing structural overview of Clinker silo and top roof girder.

Figure 1: Structural overview: Clinker silo top roof girder and radial girders

Step involved for erection of Clinker silo structure

Steps Description
Step-1 Temporary structure fabrication and erection
Step-2 18 no rafter assembly
Step-3 Ring Beam assembly with temp Hand-railing and Ch. Plate
Step-4 Ring Beam assembly erection and alignment
Step-5 4 no fixed rafter to be assembled with ring beam & alignment
Step-6 4 no double rafter to be assembled with ring beam
Step-7 Tie members to be connect with rafter
Step-8 Balance 6 no rafter to be assemble with ring beam
Step-9 Balance tie and bracing to be assemble with rafter
Step-10 Bolt torquing
Step-11 Purlin will be erected separately after dome erection
Step-12 600 Ton crane assembly with combination of boom length 54 + 36 mtr

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Step-15 TPI of crane after assembly

Step-16 18 no base plate erection and locking at 32.8 mtr level
Step-17 Erection of roof structure
Step-18 Erection of balance tie, bracing and purlins
Step-19 Erection of 5E2-BF06
Step-20 Erection of 5E2-FN06
Step-21 Erection of Penthouse with sheeting
Step-22 Erection of chimney of Bag filter
Step-24 Erection of EOT with girder
Step-25 Clinker silo sheeting

Site assembly Plan: As per site assessment all the structures will be assemble in ground
level as per convenience. We have identified the location for rafter assembly and crane
movement as per below sketch.

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Installation of Structure:
Erection weights are below:

Sl No Items Qty (Nos) Weight/ Unit (Ton) Weight (Tons)

Lift 1 Clinker Silo – Dome Structure 1 169
1 Ring Beam (with Ch. pl) 1 52 52
2 Rafter 18 4.5 81
3 Bracings 1 24 24
4 Fasteners 2
Lift 2 Clinker Silo - Penthouse 1 50

Design Consideration: Designing and assembling a clinker silo roof at ground level before
erecting it at a height of +32.40 M involves several critical considerations to ensure
safety, structural integrity, and efficiency. Here are the key factors to keep in mind:

Ground-Level Assembly Considerations

A. Pre-Assembly Planning:
 Detailed Drawings: Ensured all components are accurately detailed in
the assembly drawings.
 Material Handling: Planed for the safe handling and storage of materials
to prevent damage.
B. Component Fabrication:
 Precision Fabrication: Ensured all components are fabricated in workshop
to precise specifications to avoid issues during assembly.
 Quality Control: Conducted thorough inspections and quality checks on
all components before assembly.
C. Assembly Sequence:
 Modular Assembly: Assembled all 18 no Rafters in modular sections
to facilitate easier handling and transportation.
 Welding and Bolting: Used appropriate welding and bolting techniques
to ensure strong and durable connections.
D.Safety Measures:
 Worksite Safety: Implement safety protocols to protect workers during
the assembly process.

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 Equipment Safety: Ensured all lifting and assembly equipment is in good

working condition and properly rated for the loads.

Erection at +32.40 Meter Level Considerations

E. Lifting and Hoisting:
 Crane Selection: Chosen 600 Ton capacity cranes with (Main boom 54 M +
Luffing boom 30 M) boom combination @ lifting capacity of 190 Ton and
reach to safely Clinker roof structure at +32.40-meter level.
 Lifting Points: 4 points at ring beam and 14 points at rafter marked on
structure as lifting points on the roof sections to ensure balanced and secure
lifting.
F. Stability and Support:
 Temporary Supports: Assembled all Tie members (except bottom tie and its
bracing) and few additional temporary supports used and bracing to maintain
stability during the erection process.
 Load Distribution: Ensure even load distribution to prevent structural
deformation or collapse.
G.Alignment and Positioning:
 Precise Positioning: Involve surveyor for alignment with reference to the silo
roof base frame distribution and level as per erection to ensure the roof
sections are positioned accurately same at ground level.
 Connection Integrity: Verify that all connections are secure and meet design
specifications.
H.Safety Protocols:
 Fall Protection: Implement fall protection measures for workers operating at
height.
 Weather Considerations: Plan erection activities considering weather
conditions to avoid delays and ensure safety.
I. Final Inspections and Testing:
 Structural Inspections: Conduct thorough inspections to ensure all components
are correctly installed and meet design specifications.
 Load Testing: Perform load testing and other quality assurance tests before
finalizing the construction.

By considering above factors, we can ensure a successful and safe assembly and
erection of the clinker silo roof at the specified height.

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Roof erection:
As per below sketch, dome structure (159 T) will be placed on RCC wall in single lift by
600 Ton crane with the combination of 54 M (Main boom) and 30 M (Luffing Boom) at
32.40 M level.

Boom Combination Radius Crane Capacity Load weight Lifting Percent

54 M + 30 M 34 M 190 MT 172 MT (incl crane 90%
accessories)

Lifting plan of roof structure with Ring Beam and Rafter

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Erection Sequence and No. 0f Lifts: -

1. Dome erection:

As per above sketch, 18 no rafter (160 T) will be assembled at the ground level with ring
platform and erected. It will be placed on 18 no base plate arranged at silo RCC wall at
32.40 m level, which will be locked at 4 fixed bearing from all the direction. After this
placement, balance tie and bracing will be fixed.

2. Equipment erection:

After placing the dome, the bag filter, fan and BC03 head drive will be erected upon ring
platform @44.00 m level.

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Rafter Lifting luges

Lifting Hook Luges - 32mm, 14 (Size - Height 300mm x Horizontal 250mm)

Top lifting - Tools and Tackles

Round Web sling - Length 10mtr - Capacity 100 MT/ 2nos.
Round Web sling - Length 10mtr - Capacity 75 MT/ 2nos.
Bow Shackles - Pin Dia 80mm / 85MT- 4Nos.

Girder Lifting - Tools and Tackles

Chain Block - 10 MT /14 Nos.
D-Shakles - Dia 38mm 17mt - 14nos.
Web sling - 12mtr - 10mt/14nos.

Counterweight
Crane Counterweight - 160MT and Super lift counterweight - 250MT

Main Hook Position

Figure 8: Main 4 Hook position detail

Crane and Tools & tackles - Details

Top Lifting luges

Lifting Hook Luges - 50 mm, 4 nos. (Size - Height 400mm x Horizontal 450mm)

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3. Penthouse erection:
As per below sketch, Penthouse assemble at ground level to minimize the WAH hazards,
It weight 50 Ton will be placed on ring beam by 600 Ton crane with the combination of
54 M (Main boom) and 30 M (Luffing Boom) at 44.00 m level after completion of all rafter
and bracing.

Boom Combination Radius Crane Capacity Load weight

54 + 30 M 34 M 190 MT 50 MT

Figure 9 Lifting plan of Penthouse

1. Manpower Access & Egress

 Access from ground to temporary platform by staircase.
 Access from ground to wall by staircase.

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 Access for Erection by staircase on scaffolding, it will be always available till

erection.
 Access from Ring beam alignment and welding by staircase from 40 to 56.30 meter.
 Access for bracing, purlin and sheeting by staircase only.
 1 no 120 feet cherry picker will be always ready for Emergency rescue.
2. Safety Control Measures
 Area should be completely evacuated and barricaded against any unauthorized
entry.
 No lifting after dark, additional lighting arrangement be done before erection.
 Arrangement of lifeline at each level (platform) so that employees/ workmen who
are on the platform (2-3) must anchor.
 There should be at least 4 Walkie talkies - 2 with rigger, one with signal man and one
with crane operator.
 One signal man who will be in cherry picker should be at a safe distance and having
Vision of crane operator and the riggers on the top.
 4 no guy rope must be fixed at ground level And ensure How and where it will be
fixed? Show in the FLRA and confirm the name who will hold it and when? Swinging
must be eliminated.
 Safe approach for man movement and lifting equipment
 Deployment of trained and dedicated team for erection and height job
 Stacking of material in well manner
 All power connection to be done by authorized electrician
 All power cable to be routed through RCCB/MCB and industrial plug top
 All power tools, lifting tools to be checked by AAA concerned person and quarterly
tested sticker to be display
 Availability of fire extinguisher
 Availability and usage of job specific PPE i.e.- hard helmet, safety shoes, hand gloves,
reflective jacket goggles, full body apron, face shield with helmet and full body
harness etc.
 Use portable ladder in secured position for ground assembly purpose, if required
 Arrangement of sufficient illumination at assembly point, approaching area,
shifting/lifting area
 Barricading at required place
 Only DMC passed crane shall be deployed to the job
 All safety gear (crane) should be in working condition as per daily checklist
 Ground stability shall be bearable to crane load (with material

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 Crane should be operated by only trained and dedicated person

 While placing of crane a flag man/dedicated helper will control the equipment
movement
 Overhead power cable should not be come contact with crane boom or material
during placing of crane either shifting of material
 Power cable should not be laid down openly on ground when the crane crossing the
area
 Do the power off identified power cable, if needed
 Provide base plate below the crawlers, if required
 All welding machine to be kept under weather protection shed
 Gas cylinders to be mounted on trolley and secured with chain, FBA shall be installed
at both point
 All scaffolding material to be in healthy condition
 Scaffold to be erected as per drawing
 All scaffolder to be experienced and well known about potential hazards and its
precaution
 Proper bracing/structure support for stable the scaffold
 Scaffold will erect under the AAA scaffolder supervision
 During erection ground area to be barricaded and all engaged person will wear FBH
 Reg tad to be display at access point during the scaffold erection
 After completion of scaffold assembly, the AAA scaffolder will inspect and provide
green tag, if any observation scaffold team will rectify it
 Before start of erection lifeline/handrail to be arranged at access approach and
resting point
 During erection lifting point and resting point shall be come under SWL
 Boom swinging area shall be obstruction free
 All lifting appliances to TPI certified, color coded and physically healthy before
shifting to the site
 After inspecting of lifting hook (thickness, welding, and position/angle) slings will be
attached with the hook
 The ground area to be barricaded
 No one should be stand under suspended load
 Man lifter boom should not be come under crane hoisting boom
 All nearby workers shall be isolated from boom swing area
 After checking of all safety aspect Lifting plan shall be signed by AAA concerned
person & rigging supervisor

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 Only dedicated rigging team shall be done rigging job

 Only dedicated and identified person will give rigging signal
 A mutual rigging signal should be established between signal man and operator
 Use batten light in dark hour
 All rigging activities to be done under LNVT/AAA rigger supervision
 Dedicated rigging team/fitter will give hand support for resting the material at
designated place
 Before release the sling the load to be properly safely landed and secured by
bolting/welding
 Hard handrail/permanent handrail to be fixed at required place
 All hand tools to be in healthy condition
 Close supervision always
 Maintain housekeeping at daily basis

3. Emergency Preparedness First aid

 Safety expert (Rigging, W@H, Rescue) will be always available.
 First Aid Kit will be placed in our Site office and at first Aid center which will display
the below mentioned image for easy identification at site.
 First aid will be given to injured person at the site.
 The name and contact number of the nominated first aider(s) will be given to all
workers to call during emergency.

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