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Section 7

Construction Planning and Methods

Information for Construction Plans

During the conceptual and preliminary engineering phase, the Regional Execution Unit OfficeConstruction Manager and/or Construction Coordinator typically provide constructability reviesand perform specific tas!s in support of the front end engineering activities on a pro"ect# $hesetas!s include but are not limited to the revie, evaluation, recommendation, and providing of inputto the folloing items%

'iting studies

(# Estimate number and classification of "obsite construction and regional office personnel thatill be re)uired for the duration of the pro"ect#

*# +nalysis of principal e)uipment supplies such as vessels, columns, boilers, turbinegenerators, and other ma"or components including%

a# 'cope of contract

b# -roposed method of transportationc# Delivery schedulesd# -rocedure for storage at "obsitee# Erection proceduresf# Responsibilities of .echtel, client, and others

# Contractual agreement including%a# Construction by .echtelb# Management by .echtel

0# -ro"ect -rocedures Manual for the section on construction and related items

1# Construction pro"ect automation planning

2# 'chedules including%a# 3ront End 'cheduleb# Milestone 'chedulec# -ro"ect 'ummary 'chedule

4# 'ite analysis including the general topography, accessibility into the site, accessibility toareas surrounding the site, services available at or near the site, re)uirements ofapplicable ordinances, regulations, and codes#

5# Revie and assist in the layout of permanent plant facilities including%a# Construction accessb# Relocation of existing facilitiesc# -ermanent facilities arrangementd# $ransportation into the sitee# -ermanent open areasf# -lant securityg# 'eage treatment facility and tiein during construction stagesh# -otential use of permanent facilities and utilities by constructioni# -reassembly and modulari6ation of permanent components and systems

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'ection 2 Construction -lanning +nd Methods

&9# Construction facilities arrangement to include draings and specifications for%a# $emporary buildingb# Concrete batch plantc# Onsite storage areasd# Construction utilities

& Engineering design and studies

&(# Estimates including%a# $rendb# -reliminaryc# -ro"ectd# 3orecasts and trends

&*# :abor relations studies re)uired by the Construction Manager

;nputs to -ro"ect Management

&0# .echtel#

&1# 'ecurity re)uirements for the site including monitoring e)uipment, security fencing, and

guard force#&2# 3ire protection facilities

$he Construction Manager and/or the 'ite Manager ill provide final approval of the above input#

Construction Planning

During the development of the pro"ect, Regional Execution Unit Construction personnelconcentrate their efforts on expanding the construction plan, or!ing closely ith designengineering, estimating, procurement, and scheduling to ensure that the input of the pro"ect teamis incorporated into the pro"ect construction execution plan#

Recommendations are made on site configuration, building arrangements, and layouts after theireffect on construction e)uipment and access re)uirements have been evaluated# -articularattention should be paid hen existing facilities ill be in operation during construction to preventunnecessary loss of productivity and schedule conflicts#

$he construction schedules initially developed are normally updated to incorporate engineeringdesign information as it develops# Refinements are then made to the activity se)uencing anddurations to reflect the most current design evolution# E)uipment supplier delivery dates are alsoincorporated to provide greater definition and accuracy in pro"ecting !ey engineering,procurement, construction, and startup milestones#

$he construction methods to be used during construction of the plant are outlined to allo designengineering and pro"ect controls to develop more comprehensive cost and schedule estimates#

-roposed construction methods should be chec!ed for compliance ith the pro"ect EnvironmentalControl -lan#

+s the detailed design progresses the construction plan should be updated to reflect the currentdesign# $he folloing detailed studies and other activities are performed to determine theoptimum construction methods, e)uipment, and facility re)uirements%

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Construction -lanning +nd Methods 'ection 2

Excavation and bac!filla# Methodb# 'e)uence

(# Deatering system =if re)uired>a# $ype of system

? Deep ells? @ell points

b# -umps? :ocation? ;nstallation se)uence ith excavation

*# 3ormor!a# $ypes of forms to be usedb# Estimate/s)uare footage by typec# 3orm yardd# Models

# E)uipment and tool re)uirements

0# ;nitial "ob start tool list

1# E)uipment, evaluate AonA versus BrentA

2# Manpoer re)uirements, by craft manual and nonmanuala# Manual

? -ro"ected from construction schedule? .ased on pro"ected )uantities? 8istorical

b# onmanual? 8istorical? Discipline and area organi6ation concepts

4# Craft manpoer availability survey in con"unction ith labor relations

5# Revie of critical crafts compare ith initial manpoer curves

a# Other construction re)uirements in the areab# -ro"ected from construction schedule

&9# uantity installation curves in con"unction ith pro"ect controls

& 8istoricala# Cost reportsb# 8istorical reports

&(# Estimates

&*# Construction layout draings are prepareda# Composite overlay draings are provided hich sho civil, electrical, and mechanical

embedded items, including a determination of both concrete and form )uantities for

each placement#b# uantities are developed for incremental field purchasing and installation of conduit,

grounding, and cable tray#c# :ighting, communications, fire alarm systems, and layout draings are prepared ith

their associated )uantity surveys#

Revie integrated data systems, telecommunications systems, and other computer systemsre)uired for the construction phase of the pro"ect#

&0# Revie subcontracts and specifications

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a# -reparation, formation, and issuance of subcontractsb# -eriodic field reviesc# Evaluation and resolution of claims

&1# -osttensioning e)uipment re)uirementsa# ac!s, buttonheaders, etc#b# @or! platformsc# Communication systems

&2# 8eavy rigging re)uirementsa# Ma"or e)uipment eights and si6esb# Crane settings relative to e)uipment locationsc# :ifting e)uipment re)uired based on a> and b>d# Rigging specifications and procedurese# 'afety of all hauling and rigging systemsf# Unloading and installingg# Monitor testing of handling and rigging e)uipment and actual heavy lifts of components

;n the course of these studies, particular attention should be given to the folloing items hichmay have a significant impact on the overall construction plan and schedule%

.uilding configurations and e)uipment arrangements established by final design should berevieed for impact on the selection of the type of construction e)uipment re)uired,particularly hoisting e)uipment#

(# .uilding configurations and construction access openings#

*# $he latest pipe elding and stress relieving techni)ues should be evaluated to establishmethods and procedures for elding large )uantities of heavy all pipe#

# + comprehensive revie should be made of the types of or! hich should besubcontracted considering possible impacts on cost and schedule#

0# + revie should be made of the craft cre si6es and installation rates re)uired for installationof large pipe and for ire and cable pulling# $his establishes the necessary start dates

for these ma"or activities and aids in the evaluation of the engineering scheduling#

1# Critical items involved in scheduling site development, excavation, concrete placement, steelerection, ire termination, and other or! re)uired to meet schedule milestones should berevieed to determine or! se)uencing and pro"ect scheduling#

Cofferdams and Caissons

@hen a cofferdam or caisson is re)uired to perform a particular phase of the or!, the designmust be revieed and approved by a )ualified design engineer experienced in the design of earthretaining structures# + detailed erection procedure should be developed for the cofferdam orcaisson construction# $he 'ite Manager, the Construction Coordinator, and the ConstructionManager should revie and approve the erection procedure for ade)uacy and should ensure that

all applicable codes, safety re)uirements, and "ob needs are met#

Dewatering

@hen deatering is re)uired, the design for the number, si6e, location, and depth of deateringell points should be designed by a )ualified engineer# Deatering system installation is normallyperformed by a specialty subcontractor# ;f it is decided that the deatering system is to beinstalled by .echtel, the installation of the re)uired ell points and deatering process should bedefined in a comprehensive construction procedure#

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Heavy Rigging Transport Road

@hen a road is re)uired for heavy rigging transport, the 'ite Manager and the ConstructionCoordinator should initiate development of a route and a heavy rigging transport procedure incon"unction ith the .:'; rigging group#

$he 'ite Manager and the Construction Coordinator revie and approve the route and thetransport procedure and ensure they meet all applicable codes, safety re)uirements, and "obre)uirements#

lasting Criteria

@hen blasting is re)uired, the blasting criteria shall be developed by a )ualified person to ensurethat the blasting can be safely perform ithout damage to ad"acent structures, earth slopes, ordi!es# $he final blasting plan should be revieed by the 'ite Manager prior to the start of blastingoperations# 'pecial permits may be re)uired from local and/or state agencies to authori6eblasting operations#

Sanitation !nd Drin"ing #ater

othing causes more manual labor unrest on a construction pro"ect than sanitation and drin!ingater facilities# Expenditures for ellplanned and maintenancefree systems ill pay forthemselves many times over throughout the course of the pro"ect#

'anitary facilities should be ade)uately si6ed for the maximum number of employees expectedduring pea! periods of construction# Disposal facilities should be ell engineered and asmaintenance free as possible# O'8+ re)uires trailers used in permanent structures must be ofnoncombustible or fire resistant construction#

-ortable toilets can be used in remote areas of the "ob or in areas here more permanentfacilities ould not be economical# ;n most areas, these can be provided and serviced through alocal contractor# On some pro"ects it may be economical to buy or rent the toilets and service

them ith .echtel labor#3or all sanitary facilities, it is mandatory that they be !ept clean and monitored for cleanliness atall times#

Drin!ing ater should be piped throughout the pro"ect here possible to eliminate the expensivedistribution of ater cans# + permanent distribution system ith electric ater coolers ill pay foritself many times over# Compare the cost of a driver, truc! and one or to craft to fill, handle, andclean the cans over the period of time needed to service the area against the cost of electricater coolers# 'pecial permits may be re)uired by local and/or state agencies prior to placing adrin!ing ater system in service#

+de)uate ater supply is very important# Use local ater supplies henever possible to eliminate

the expense of maintaining a ell and treatment facilities# @hen ell and treatment facilitieshave to be provided, they must meet the re)uirements of local codes and regulatory agenciesand be ade)uately si6ed for the maximum number of employees expected during pea! periods ofconstruction#

@hen a ell is provided, it ill also probably have to supply construction ater and fire protectionater# $he total capacity re)uirements should consider all potential uses and should beengineered to be as maintenance free as possible#

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House"eeping !nd Trash Removal

8istorically, "ob costs have demonstrated that a pro"ect ith poor house!eeping%

8as higher costs

8as a poorer safety record

8as higher material handling costs

8as loer morale

$he 3ield 'uperintendent is responsible for enforcing house!eeping standards on the pro"ect#Each craft should be re)uired to cleanup after themselves on an ongoing basis to eliminate costlyFcleanup daysB#

@henever possible, trash should be disposed of ithin the security fence in much the samemanner as municipal dumps are operated# @hen appropriate permits can be obtained, theexcavation of a pit that can be expanded ill do the "ob# 'ufficient material from the excavationshould be left close by to cover and bury the trash# @hen burning permits are alloed by localregulations, they should be obtained so the volume of materials to be buried can be reduced#

@hen trash has to be disposed of off the site, very close control has to be maintained for securityreasons# ;nspection and monitoring of this or! is mandatory to prevent e)uipment, tool, andmaterial losses#

-rior to any burying, burning, or removal of aste materials, consult ith .echtel Environmentalfor proper permit re)uirements# +ll contracted aste haulers must be appropriately licensed andhaul only to an approved, licensed facility#

$nvironmental

$he Environmental re)uirements for the pro"ect are revieed during the front end planning part ofthe pro"ect for items hich have construction impact# ;f a list of these items has not beenprovided, the 'ite Manager develops a list of environmental items that ill impact the construction

on the pro"ect# ormally, this list ould involve measures to prevent pollution of air, ater, or soilby ha6ardous astes, oil, or silt# $he ma"ority of the re)uirements are directed by federal, state,and local regulations# +ll !ey construction team members should be informed of the pro"ectspecific regulations#

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$mergencies

$he pro"ect should develop an Emergency -lan to cover the folloing emergencies%

.omb $hreats

Explosions

Operating -lant Upset

Oil 'pills

3loods

Earth)ua!es

8urricanes

$ornadoes

Civil/:abor Disturbances

Once the plan is in place, materials should be purchased, personnel trained, and the necessaryinstructions posted to inform all field personnel of emergency actions re)uired to implement theplan#

$his information must be included in the pro"ect 'afety and 8ealth +ction -lan#

Manual %a&or Training Program

+t the discretion of the 'ite Manager, brief, informal training sessions may be instituted in the fieldto improve the s!ills and increase productivity of field manual labor# 3ield personnel, both manualand nonmanual, s!illed in the various discipline specialties may be designated by the 'iteManager or other field supervision as instructors#

+ Manual Craft $raining -rogram Coordinator, reporting to the 3ield 'uperintendent is responsiblefor the formulation of a training curriculum, ith assistance from the designated instructors, and in

line ith the pro"ect needs# $he -rogram Coordinator is responsible for the scheduling of trainingsessions to ensure a minimum of interference ith construction operations and for maintainingtrainee records# $raining sessions may include actual onthe"ob training herein trainees or!ith s!illed craft in performing construction operations#

+ll employees must receive safety and health training hich ill enable them to identify and eitheravoid or control any ha6ardous condition or or! practices# $his training must be detailed in thepro"ect 'afety and 8ealth +ction -lan#

$he curriculum for a manual labor training program may include the folloing%

SUPERVISION

3oreman Duties and Responsibilities

General 3oreman Duties and Responsibilities'uperintendent Duties and Responsibilities3ield Engineering Duties and ResponsibilitiesCost Control'chedule Control

CIVIL

Concrete -lacing E)uipment and MethodsHibration of Concrete3ormor! 3abrication and ;nstallation


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3inishing ConcreteCuring Concrete@eather -rotection of Concrete-lacing Reinforcing 'teelMechanical 'plicing of Rebar'tud @elding'tructural 'teel Erection 'e)uencing and Rigging

.olting Up 'tructural 'teel$endon 'heathing ;nstallation-ost$ensioning Operations-lateor! Erection

ELECTRICAL

Cable -ullingGroundingCable $erminationsRigging and 'etting E)uipmentCircuit Chec!out

MECHANICAL

-iping Erection and 'e)uencing@elding $echni)ues and Re)uirements-iping 'ystems 3lushing and Cleaning-iping 'ystem :ayout

+lignment Methods and $echni)uesRigging and 'etting E)uipment

'ource material for many of the above sub"ects may be found in the construction section of theOn:ine Reference :ibrary and various brochures and informational media hich may beobtained from suppliers upon re)uest#

Manual %a&or Procedures

$he 'ite Manager should establish ob"ective standards for or!ing habits, productivity, andgeneral conduct of manual labor ith the 3ield 'uperintendent, !ey lead Discipline'uperintendents and the :abor Relations Representative# $he purpose of these standards is toensure that management rights are not abdicated# $he standards should cover at least thefolloing%

Establish the rules for ordering of craft# Designate ho ill be responsible for placing craftstaffing re)uests ith the local and ho ill place orders ith the local hen theprimary person responsible for this activity is absent# otify the locals in riting of thenames of people ho are authori6ed to place craft staffing re)uests for the pro"ect#

(# Establish the company

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2# Establish the type of supervision needed hen or!ing overtime# Ensure nonmanualsupervision is aare of the re)uirements#

4# Establish the number of craft ho can be or!ed ithout manual supervision# Ensure nonmanual supervision is aare of the re)uirements#

5# Establish hen or!ing 3oremen can be utili6ed and hat or! they may perform#

&9# Establish procedures to ensure that all steards or! unless on Union business =chec!in/out procedure ith supervisor>#

& Establish policy for General 3oremen to not use 3oremen on overtime except hen neededto supervise or!#

&(# Establish policy on rotating overtime beteen craft, distribution of overtime to be determinedby 'upervisor#

&*# Establish rules that speciali6ed craft =such as ;#@# connectors> cannot be replaced by nonspeciali6ed craft if overtime is of a speciali6ed nature#

Establish procedure for termination of craft, including procedures for determining reductionin force terminations#

&0# Establish plans for ratio of craft per 3oreman and 3oremen per General 3oreman#

&1# Establish policy of only using elder helpers hen it is deemed necessary to efficiently andsafely perform elding operations#

&2# Establish procedures for hiring ne employees to determine acceptance or re"ection ofapplicants#

&4# Establish procedures to orient ne employees ith the pro"ect site "ob rules, and securityrules#

&5# Establish procedures to ensure that each ne 'uperintendent receives a copy ofappropriate labor agreements, or! rules, pre"ob conference minutes, and similarmaterials#

(9# Establish procedures to control tool, e)uipment and material loss#( Establish procedures for determining under hat conditions company must replace

employee personal tools#

((# Establish procedures to ensure employees provide tools they are re)uired to supply# Re)uireindividual inventory as prere)uisite to employment#

(*# Establish procedures for use of craft labor on receiving and inspecting materials ande)uipment#

(# Establish procedure for handling of grievances at the "obsite#

(0# Establish "obsite reporting procedures for labor disputes#

(1# Establish security procedures to control entry and exit from "obsite by manual personnel#

(2# Establish procedures for dealing ith unusual or!ing conditions contained in local laboragreements#

(4# Establish procedures for subcontractor reporting of labor problems#

(5# Establish procedures to control vacations and other approved leaves of absence#

*9# Establish procedures to ensure the proper training of apprentices and personnel in othertrainee classifications#


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* Establish procedures for providing personnel ith meals hen re)uired to or! overtime#

*(# Establish hat or! ill re)uire safety clothing and the procedures for issuance and use toprevent abuse#

**# Establish hat or! ill re)uire rain gear and the procedures for issuance and use toprevent abuse# Jeep an ade)uate supply to minimi6e lost time due to eather# Raingear is issued for "obsite use, not to ear home#

*# Establish that or! planning and craft deployment is done through the General 3oreman at atime other than at the start of the shift#

*0# Ensure that the General 3oreman is in the or! area at the start of each shift#

*1# Establish policy of proper approval and notification of crafts involved prior to overtime or!#;nclude the furnishing of first aid, re)uirements for meals, etc#

*2# Establish that no overtime is or!ed ithout approval including during the lunch period#

'on(Manual Responsi&ilities

$he 'ite Manager should establish ob"ectives and "obsite policy for or!ing habits, productivityand general conduct of nonmanual personnel ith the 3ield 'uperintendent, Jey :ead Discipline'uperintendents and Jey :ead Engineers# $his policy should ensure that all !ey supervisorypersonnel are fully committed to the folloing%

$he entire construction team is responsible for pro"ect safety#

(# $he entire construction team is responsible for )uality of or!#

*# Revie draings, specifications, and scope of or! prior to starting or!#

# Observe "ob procedures for ordering tools and materials#

0# Ensure that or! is performed in accordance ith draings and specifications#

1# Ensure that or! is performed in accordance ith Engineering instructions or procedures#

2# Observe procedures for initiating bac! charges and ensure that correct time, material ande)uipment are charged#

4# Jno the pro"ect cost code of accounts#

5# Jno, enforce and control distributable labor hours#

&9# Jno and be involved in the cost and schedule controls for the pro"ect#

& Monitor and maintain safe or!ing conditions#

&(# Jno and enforce O'8+ re)uirements#

&*# Jno and enforce fire protection re)uirements#

Jno and enforce pro"ect security procedures#

&0# Read and understand site procedures#

&1# Read and understand the scope of subcontracts#

&2# Read and understand eld rod control and elding procedures#

&4# Ensure that staff is composed of )ualified, !noledgeable personnel#

&5# Delegate authority to loest level possible to enable proper accomplishment of tas!s#

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(9# Counsel and meet ith subordinates to resolve difficulties and problems, motivate personneland improve morale#

( Re)uire good or! practices from the crafts#

((# -romote efficiency, labor productivity, and maintain schedule commitments#

(*# Jno that the 'ite Manager, 3ield 'uperintendent, and the :abor Relations Representativeare the only persons at the site authori6ed to communicate ith Union .usiness +gents#

)ield Procedures ( Documents and Manuals

$he folloing represents a list of documents and manuals available on the On :ine Reference:ibrary hich the 'ite Manager should obtain, maintain, and use as guides to develop fieldprocedures%

Corporate -olicies Manual

(# Corporate Management ;nstructions, Holume ; K ;;

*# Corporate 8uman Resources Manual =Red .oo!>

# .echtel Construction Operations, Operating ;nstructions

0# .echtel Construction Operations 'ite Managers Manual

1# .echtel Construction Operations 3ield Engineering Manual

2# .echtel Construction Operations Construction uality Manual

4# 'afety and 8ealth Manual, Holume ; K ;;

5# .echtel Construction Operations -rinciples of 3ield Controls Manual

&9# .echtel :easing 'ervices, ;nc# =.:';> E)uipment Catalog

& -rime Contracts Manual

&(# Contracts 3ormation Manual

&*# Contracts Management Manual

Contracts +dministration 8andboo!

&0# 3ield -rocurement Manual

&1# .echtel uality Control Manual +'ME ; K H;;;

$he 'ite Manager should obtain copies of the folloing industry standards for the pro"ect%

+'; 'tandards

(# O'8+ 'tandards

*# 'tandard Codes =+;'C, +C;, EC, +';, etc#>

$he 'ite Manager should also obtain copies of the folloing pro"ect specific documents for use indeveloping site procedures and controls%

+ conformed copy of the Contract

(# Contract $echnical 'cope Document

*# -re"ob Conference otesL urisdictional Mar!up Minutes

# -ro"ect -rocedures Manual

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0# -ro"ect -rocurement Manual

1# -ro"ect Code of +ccounts

%egal and Insurance Pro&lems

$he insurance arrangements for each pro"ect vary and are established based on the provisions ofthe contract beteen .echtel and the oner and upon the underriting characteristics of the

or!# $he pro"ect execution plan should address ho legal and insurance problems ill behandled#

$he .echtel ;nsurance Department prepares the pro"ect insurance premium structure based onthe location and the nature of the or!#

$he ;nsurance and :egal departments compliment each other and must be contacted in case of aproblem such as interpretation of the contract, accident claims, claims for extras, lasuits,licensing re)uirements, subcontractor termination for default, or insurance re)uirements forsubcontracts is !non or suspected# $he 'ite Manager is responsible for notifying the insuranceand legal departments of any potential problems encountered on the pro"ect# Revie andcomment on the solution and/or action should be revieed ith the Construction Manager prior toimplementation# 3inal approval alays must be furnished by the :egal and ;nsurancedepartments#

*o& Security

$he primary consideration for a basic "obsite security program is complete perimeter control# $he'ite Manager is responsible for deciding on the type of security system that ill be used on thepro"ect and for coordinating the implementation of the system ith the oner hen re)uired# $he3ield 'uperintendent is typically assigned responsibility for directing the implementation of sitesecurity#

$he type and level of security re)uired varies ith each pro"ect and defined in the pro"ect securityplan hich is developed at the start of the pro"ect# $he .echtel security group establishes

guidelines that are used in the development of this plan and at some international locations isassigned the responsibility for developing the plan# $he 'ite Manager and 3ield 'uperintendentprovide input and comments to the site security plan since it ill have a significant impact ontemporary facilities layout# $he final plan must be revieed and approved by the 'ite Managerand Construction Manager#

$he 'ite Manager is also responsible for timely reporting of the folloing situations in accordanceith the approved pro"ect security plan%

+ny ma"or criminal offense

(# +ny ma"or losses

*# +ny act of sabotage

# +ny acts of gross negligence

Pro+ect Close(out

-ro"ect closeout is the responsibility of the 'ite Manager and should be addressed during thedevelopment of the construction execution plan# -ro"ect closeout must consider the folloing%

Disposition of temporary facilities

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(# Disposition of pro"ect documents, draings, and correspondence

*# Removal of e)uipment and small tools

# Reassignment and/or termination of pro"ect construction personnel

Historical Cost Report

This report is initiated by the Site Manager and the ProjectControls Supervisor and should be considered at the start of the

project in the construction execution plan to ensure that the

required records are maintained throughout the duration of the

project. The report describes pertinent job details and shows

final job costs. The Project Controls Supervisor is responsible

for generating the report and for obtaining approval of the Site

Manager and the Project Manager. The final report is normally

issued when construction has been completed and the field forces

have been demobilied.

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