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METHOD STATEMENT STATEMENT Method Statement No.
Method Of Statement For Pipe Pi pe Laying Works
01/Rev.1 Subject : Method Statement and Qa!ity P!an For Pipe Laying " Mi!d Stee! Pipe Issuance Date: 16/2/2012 Effective Date:
16/2/2012
#$% #$% &ene &enera ra!!
1) he objective of this method statement is to e!abo"ate on the #o"$s %"ocedu"e fo" !a&in' mi!d stee! %i%es and its associated #o"$s. 2) To outline preparation preparation or coordination coordination required required before before start work 3) To outline the sequence sequence of work or construction construction methodology methodology for Water Water Supply Works Works (S!" #ipes)$ ethodology ethodolog y start from hauling% stacking and handling of pipes% pipe laying% road works% works% etc until completion of the the &nal testing and commissioning commissioning system and as built drawings$ ') To outline quality quality plan or inspection test test required required during proect proect implementation$ implementation$ ) To perform safe safe working en*ironment en*ironment and compliance compliance to the safety requirements requirements$$ '$% Prepar Preparati ation on Wo Works rks 2.1 (ounda"&/Ri'ht of #a&s )R*+, %e's- #i!! be estab!ished b& !icensed su"ve&o" and the nde"'"ound ti!ities Ma%%in' )((M, ((M, #i!! be ca""ied out to estab!ish an eistin' unde"'"ound se"vices co""ido". 2.2 he a!i'nment of the %"o%osed %i%es%i%es- in this case 00mm %i%e to to (u$it e%is Rese"voi" and the 300mm %i%es to (u$it aisho Rese"voi" #i!! be dete"mined based on the info"mation 'athe"ed f"om the ((M and ((M and submit to the S* fo" a%%"ova!. 2.4 he %i%e a!i'nments #i!! then be %e''ed on the '"ound '"ound once the S*5s S*5s a%%"ova! is obtained. obtained. 2. he "e!evant autho"ities autho"ities #i!! then be invited invited to visit the site to chec$ if the the %e''ed a!i'nment a!i'nment meet thei" "e7ui"ement. 2. 8n& "e!ocation of unde"'"ound se"vices #i!! be ca""ied out %"io" to to the commencement of the %i%e !a&in' #o"$s and the #o"$ sha!! be ca""ied out b& eithe" "es%ective se"vices %"ovide"s o" b& the %i%e !a&in' cont"acto" as a va"iation va"iation o"de" #o"$ as the"e is no %"ovision of "e!ocation of unde"'"ound se"vices in the cont"act. cont"act. 2.6 9"io" to sta"tin' of an& %h&sica! #o"$s on on site the 9e"mit/8%%"ova! 9e"mit/8%%"ova! f"om the "e!evant autho"ities autho"ities shou!d be '"anted and a!! conditions im%osed b& them to be st"ict!& adhe"ed befo"e an& const"uction #o"$ be'ins. 2. 8ccess "oad to #o"$in' %!ace #i!! be avai!ab!e avai!ab!e fo" accessibi!it& of %i%e !a&in' team team and associated const"uction team. 2.3 8!! mate"ia!s- such as sand- c"ushe" "un that need to be inco"%o"ated in to to the #o"$s #i!! be stoc$%i!e at st"ate'ic !ocations that #i!! not obst"uct the the %ub!ic access and #i!! not affect the stabi!it& of an& st"uctu"e. hese mate"ia!s #i!! eventua!!& be t"ansfe""ed to the %i%e !a&in' !ocation fo" t"ench fi!!in' %u"%ose b& means of dum% t"uc$s. 2.; em%o"a"& su%%o"ts #i!! be %"ovided to %"otect a!! a!! eistin' se"vices. 2.10 +o"$in' %!atfo"m on uneven '"ound #i!! be %"e%a"ed eithe" b& "emova! of su"%!us ea"th o" bac$fi!!in' #ith im%o"ted ea"th. 2.11 2.11 If "e7ui"ed- tem%o"a"& sho"in' ma& be em%!o&ed to %"event dama'e o" co!!a%se of s!o%e o" adjacent st"uctu"es o" se"vices. 2.12 8!! necessa"& %i%es- fittin's- s%ecia!s #i!! be made avai!ab!e and st"un' a!on' the %i%e!ine "outes %"io" to the commencin' of %i%e !a&in' #o"$s. 1
)$% Ha!ing* Sta+king and Hand!ing of Pipes 4.1 9i%es du"in' de!ive"& and #hen in t"ansit a"ound the site sha!! be su%%o"ted on th"ee "ubbe" cove"ed sadd!es sha%ed to 'ive at !east ;0< ci"cumfe"entia! su%%o"t and sha!! be fi"m!& he!d in %osition at each sadd!es b& st"a%s ti'htened b& tu"nbuc$!es in such a manne" that the inte"na! coatin' is not dama'ed. *ne sadd!e sha!! be at the cente" of the %i%e !en'th and the othe" t#o sha!! each be %ositioned at a distance one=fifth of the %i%e !en'th f"om each end of the %i%e. 4.2 >iftin' of %i%es on site sha!! be b& means of "einfo"ced canvas s!in' #ith minimum 400mm #ide to %"otect a'ainst the dama'e of the ete"na! coatin'. he canvas s!in' #i!! be %osition at a%%"oimate!& one=fifth of the %i%e !en'th f"om each end of %i%e befo"e !iftin'. 4.4 9i%es de!ive" to site sha!! be st"un' a!on' the %i%e!ine "outes. *n uneven '"ound the %i%es #i!! be su%%o"ted on sand ba's o" ea"th bunds #hich 'ive continuous su%%o"t unde" not !ess then 0
%on confi"mation of the %"o%osed %i%e "oute as %e" item 2. above the ecavation fo" the %i%e #i!! commence. Ecavation fo" %i%e t"ench #i!! be ca""ied out b& means of bac$hoe ecavato" o" h&d"au!ic ecavato". Ecavation is c!ose!& monito"ed to %"event ove" eca vation. *nce ecavation is com%!eted- the "educed !eve! at the bottom of the t"ench is ta$en. his is "e7ui"ed fo" com%utation of the ecavated mate"ia! and fo" com%!iance to the desi'ned %i%e !eve!.
.1.2
8t a"ea #ith bad '"ound condition- a%%"o%"iated sho"in' sha!! be %"ovided to avoid the sides of ecavated t"ench f"om co!!a%se and ensu"e safe #o"$in' condition #ithin the %i%e t"ench.
.2 De#ate"in' of %i%e t"ench .2.1
8t a"ea #ith hi'h #ate" tab!e o" du"in' "ainin' season- de#ate"in' %um% sha!! be used to "emove #ate" #ithin the %i%e t"ench in o"de" to %"ovide a #o"$ab!e condition fo" the %i%e!a&in'- #e!din' and othe" associated #o"$s #ithin the %i%e t"ench.
.4 9i%e !a&in' .4.1
9i%e !a&in' #i!! be ca""ied out as soon as t"enchin' is com%!eted. 9i%e to be !aid #i!! fi"st be ins%ected fo" dama'ed of ete"na! #"a%%in' and #e!ded ends to be #i"e b"ushed c!ean to "emove mud/ di"t befo"e %!acin' into %osition.
.4.2
9i%e #i!! be !aid to the !ines and !eve!s sho#n on the d"a#in's o" as othe"#ise di"ected b& S*. he a!i'nment fo" !a&in' of %i%es #i!! st"ict!& fo!!o# the a!i'nment %e's 'iven b& the su"ve&o".
.4.4
9i%e sha!! be !ifted b& usin' "einfo"ced canvas s!in' and s!o#!& !o#e" do#n to the t"ench unti! a%%"oimate!& 0mm above the fo"mation !eve! of the t"ench- in the !ifted %osition. he a!i'nment of the %i%es is adjusted acco"din' to the "e7ui"ement and the %i%e mouth is b"ou'ht c!ose" to the othe" %i%e mouth #hich has a!"ead& been !aid. *nce both %i%e mouths a"e a!i'ned- the !ifted %i%e is %ush to#a"d the !aid %i%e b& means of ecavato" buc$et to a!!o# the %i%e mouths to en'a'e. *nce this is done- the %i%e is fu!!& !o#e" do#n and
2
the s!in' be!t is "emoved. Recess sha!! be %"ovided du"in' the t"ench ecavation to faci!itate the "emova! of s!in' be!t. . +e!din' 9"ocedu"e ..1
he #e!din' machines to be used fo" the #e!din' of the joints #i!! be Mi!!e" )00am%,. he e!ect"ode used #i!! be f"om M*? +e!din' 9"oduct Sdn (hd o" e7uiva!ent. he 'au'e of e!ect"odes #i!! be 4.2mm fo" the initia! "oot "un and fina! "un of the 00mm %i%e. 8s fo" the 300mm %i%e the 'au'e of the e!ect"odes #i!! be .0mm fo" both the "oot and fina! "uns. he di"ection of the #e!d #i!! be f"om bottom )u% hand, u%#a"ds to the to% of the %i%e and the com%!eted fi!!et #e!d #i!! be fu!! and conve in sha%e.
. +e!din'
..1
+he"e the stee! %i%es a"e to be joined b& #e!din' it #i!! be b& means of an inte"na! and an ete"na! ci"cumfe"entia! e!ect"ica! a"c #e!d at each %oint. @o" 00mm %i%e- on!& ete"na! ci"cumfe"entia! #e!din' is "e7ui"ed base on s%ecification. @o" 300mm %i%e inte"na! and ete"na! ci"cumfe"ence #e!din' a"e "e7ui"ed.
..2
(efo"e %!acin' the %i%es to'ethe" the %o"tion of the soc$ets and s%i'ot to be #e!ded #i!! be c!eaned to a b"i'ht meta!!ic finish- the s%i'ot end #i!! then be %!aced in the soc$et and fo"ced inside so that the s%he"ica! su"faces a"e in contact and that the 'a% bet#een the %i%es at the end of the s%i'ot is no#he"e '"eate" than 1.mm.
..4
+he"e %i%es a"e to be joined b& a stee! s%!it co!!a"- the %i%e ends and the co!!a" #i!! be c!eaned to b"i'ht meta!!ic finish. he co!!a" #i!! then be %!aced on the ends of the %i%e so that the s%ace bet#een the %i%e ends #i!! be about 2mm f"om the cente"!ine of the co!!a". he co!!a" #i!! be c!am%ed ti'ht!& onto %i%es usin' the !u's and #e!ded !on'itudina!!&. 8fte" com%!etion of the ci"cumfe"entia! #e!ds- the !u's #i!! be "emoved and the !on'itudina! #e!d com%!eted.
..
he #e!d #i!! be conve fu!! fi!!et t&%e fo" !a% #e!ded joints made b& the meta! a"c %"ocess usin' a%%"oved t&%es of e!ect"odes. Each time thei" a"c is sta"ted it #i!! be mani%u!ated to obtain com%!ete fusion of the #e!d meta! #ith the %i%e meta! and an& %"evious!& de%osited #e!d meta!.
..
(efo"e #e!din' is ove"- an& %"evious!& de%osited meta! #i!! be com%!ete!& "emoved and the #e!d meta! and the adjacent %i%e meta! #i!! be c!eaned b& #i"e b"ushin'.
..6
@o" 300mm %i%e- ai" test on the joint #i!! be ca""ied out. 1ba" of ai" %"essu"e #i!! be a%%!ied to the #e!ded joint fo" a du"ation of 10 minutes. 8n& #e!din' defects obse"ved #i!! be "e%ai"ed unti! the"e is no mo"e ai" !ea$a'e.
.6 Sheathin' to #e!ded joints
3
.6.1
%on #e!din' of joints- the ba"e meta! at the joints #i!! be tho"ou'h!& c!eaned to a b"i'ht meta!!ic finish and #i!! be immediate!& coated #ith %"ime" so!ution usin' b"ush. 8s soon as the %"ime" is set- the sheathin' #i!! be com%!eted b& usin' Denso a%e.
.6.2
@o" the inte"na! of 300mm %i%e - cement !inin' of mi 1:4 #i!! be a%%!& on a!! ba"e meta! of the same thic$ness #ith eistin' %i%e !inin'.
. Refi!!in' of t"ench ..1
"ench fi!!in' #i!! on!& be ca""ied out u%on ins%ection b& S* o" his "e%"esentative.
..2
Suitab!e ecavated mate"ia!s #i!! be de%osited in !a&e"s and "ammed into the %i%e t"ench #ith suitab!e sha%ed "amme"s.
.3 Re%!acement of unsuitab!e mate"ia! .3.1
@o" ce"tain a"eas #ith bad soi! condition- ea"th u%on the t"ench ecavation !imit mi'ht need to be "emoved and "e%!aced #ith suitab!e mate"ia! as di"ected b& S*.
.3.2
he unsuitab!e soi! #i!! then be ecavated and ca"t a#a& f"om site. 9"io" to bac$fi!!in' of suitab!e mate"ia!the "eceivin' '"ound must be ins%ected and a%%"oved b& S*.
.; Road +o"$s .;.1
8s the %i%e a!i'nment is main!& on the "oad shou!de" the a"ea of %"emi is on!& confined to the access "oad into !ots and the a"ea fo" each ecavation is sma!!. @o" the %"emi a"ea- u%on com%!etion of %i%e !a&in' the t"ench #i!! be bac$fi!!ed #ith suitab!e '"anu!a" mate"ia!s to the soffit of the sub=base #hich is 0mm be!o# the to% of the "oad. he bac$fi!!ed mate"ia!s sha!! be com%acted #ith suitab!e vib"atin' "o!!e".
.3.2
A"ushe" "un #i!! then be %!aced on the com%acted %i%e t"ench in t#o !a&e"s of 22mm thic$ and com%act acco"din'!& . 9endin' on the avai!abi!it& of the %"emi f"om the 7ua""&- sometime it mi'ht not be %ossib!e to %"emi the ecavated %"emi a"ea on the same da& in cases !i$e this the c"ushe" "un #i!! be fi!! to the same !eve! as the eistin' %"emi - and come bac$ to "edo the %"emi "oad on othe" da&.
.;.2
8 !a&e" of bituminous tac$ coat #i!! then be s%"a&ed ac"oss the com%acted sub base and a !a&e" of binde" cou"se of 60mm thic$ #i!! be s%"ead manua!!& ac"oss the sub base and com%act usin' vib"atin' "o!!e".
.;.4
he 0mm thic$ #ea"in' cou"se #i!! be a%%!ied at a !ate" sta'e. he same %"ocedu"e #i!! be a%%!ied.
.109i%e cuttin' .10.1
+he"e it is necessa"& to cut %i%es fo" c!osin' !en'ths o" fo" the %i%e s%ecia!s- the cuttin' #i!! be neat!& and accu"ate!& %e"fo"med b& usin' suitab!e too!s.
-$% QA.Q/ 0e+ord of Works 4
.1 Reco"d fo" %i%e !a&in' #i!! be !o''ed fo" t"ace abi!it& in a %i%e=!o'. he %i%e=!o' #i!! be fi!!ed in b& the site su%e"viso" and ve"ified b& the S*5s "e%"esentative. he %i%e=!o' #i!! contain the fo!!o#in' info"mation:= .1.1
Inve"t !eve! of t"ench- %i%es and '"ound !eve! )befo"e ecavation and afte" bac$fi!!in',
.1.
+e!din' detai! inc!udin' #e!de"5s name- time #e!din' sta"ted and com%!eted
.1.3
Schematic of %i%e joint- t&%e of joints
.1.;
Ahec$ bo fo" sand fi!!in'
.1.10
Ahec$ bo fo" conc"ete su""ound
1$% Water tightness test 6.1 8fte" a !en'th of %i%e!ine has been com%!eted- it #i!! be #ate" ti'ht tested a'ainst sto% ends. he testin' #i!! be ca""ied out at a%%"oimate!& 2 $m in !en'th in bet#een #ashouts o" ai" va!ves. he sto% ends #i!! be c!osed b& a%%"oimate!& end ca%s #ith sufficient st"en'th to #ithstand the test %"essu"e 6.2 he #ate" sou"ce fo" the #ate" ti'htness test #i!! be obtained f"om adjacent #ate" %i%e !ine o" f"om the st"eam #he"e afte" f"om Eistin' %i%e !ine is not avai!ab!e. If st"eam #ate" is ta$en- it #i!! be f"ee f"om si!t- contamination and %o!!ution and a'"eed b& S*. 6.4 Bene"a!!&- the %i%e st"etch to be test is fu!!& fi!!ed #ith #ate". %on fi!!in' u% the %i%e!ine- it #i!! be !eft fo" 2 hou"s fo" abso"%tion of #ate" b& the cement !inin' to ta$e %!ace. Du"in' this %e"iod- ins%ection #i!! be ca""ied out at a!! f!eib!e joints. 8& !ea$a'e at these joints #i!! be "ectified immediate!&. %on com%!etion of "ectification an !a%se of 2hou"s since the %i%e!ine is com%!ete!& fi!!ed u% #hicheve" !ate"- '"adua!!& inc"ease the %"essu"e #ithin the %i%e usin' a %"essu"e %um% to the desi"e testin' %"essu"e. Rectified the f!eib!e joints if an& !ea$a'e found. If no !ea$a'e found- %"oceed #ith the test b& monito"in' the %"essu"e 'au'e fo" 2 hou"s. 8fte" 2 hou"s- "einstate the %i%e %"essu"e to the testin' %"essu"e. Measu"e the vo!ume of #ate" used fo" "einstatin' the testin' %"essu"e. his vo!ume of #ate" #i!! "e%"esent the vo!ume of #ate" !ea$ed th"ou'h the %i%e du"in' the 2hou"s. If the !ea$a'e does not eceed 0.0 !ite" %e" mm of inte"na! diamete" %e" 2 hou"s %e" $i!omete" of %i%e!ine- the !ine is deemed to have %assed the #ate" ti'htness test. 6. Detai! method statement fo" #ate" ti'htness test fo" each st"etch of %i%e!ine to be submitted se%a"ate!& fo" S* a%%"ova! %"io" to the actua! #ate" ti'htness test at site.
2$% Steri!isation and F!shing of Pipe!ines .1 %on com%!etion of %"essu"e testin'- c!eanin' and connection of the %i%e to the out!et at ua!a Ce!ai +ate" "eatment )WTP,%!ant to the "es%ective "ese"voi"s the ste"i!iation of the %i%es can commence. he ste"i!iin' a'ent to be used fo" the ste"i!iation #i!! be ca!cium h&%och!o"ide)/aH/!, of 6 concent"ation. AaFA! so!ution of 20m'/! concent"ation )%"e 5
mied, #i!! be injected into the %i%e via the ai"va!ve tees at %"edete"mined !ocation to achieve maimum uti!iation. *nce the AaFA! so!ution is injected into the %i%e a!! the ai"va!ve #i!! be insta!!ed bac$ed to the tees. he %i%e #i!! be fi!!ed #ith #ate" f"om the +9. *nce the %i%e is fi!!ed the va!ve at the +9 #i!! be c!osed and !eft fo" 2 hou"s. 8n ins%ection of the %i%e!ine #i!! be ca""ied out to asce"tain that a!! the va!ves a"e c!osed. he #ate" sam%!es #i!! be ta$en afte" 2 hou"sshou!d the sam%!e sho#n a ch!o"ine content of 0.2%%m then the %i%e!ine is conside"ed ste"i!ied. he %"ocess #i!! be "e%eated unti! 0.2%%m is achieved. .2 %on the com%!etion of %a"t .1 above the f!ushin' of the %i%es can commence. he scou" va!ves discha"'e di"ect!& into #ate" cou"ses #i!! be o%en fu!!& to f!ush the %i%e unti! the #ate" is c!ean. .4 he #ate" fo" Ste"i!isation G @!ushin' #i!! be %"ovided f"ee of cha"'e.
3$% As 4i!t dra5ings 3.1 %on the com%!etion of the #o"$s the as bui!t d"a#in's #i!! be %"e%a"ed. 8s the a!i'nment #i!! in most cases fo!!o#ed the %e' %e''ed b& the !icensed su"ve&o"- the othe" info"mation that "e7ui"ed fo" the %i%e!ine as bui!t d"a#in' is the as bui!t inve"t !eve! of the %i%e. his info"mation #i!! be "eco"ded on the Dai!& %i%e !o' and #i!! be %ass to the !icensed su"ve&o" fo" thei" %"e%a"ation of the as bui!t. he Su"ve&o" #i!! %"e%a"e the d"a#in' based on the %i%e !o' and a!so ca""ied out fie!d su"ve& fo" the #o"$s. 6$% Safety measres ;.1 +o"$e"s shou!d #ea" a%%"o%"iate %e"sona! %"otective e7ui%ment )99E, ;.2 S#in' a"ea of heav& machine"& to be monito" c!ose!&. ;.4 Ahec$in' of #i"e "o%e- #ebbin' s!in' and too!s a"e in 'ood #o"$in' condition. ;. 8de7uate !i'htin' if #o"$in' du"in' ni'httime. ;. Ecavated %it/ t"ench #i!! be ins%ected b& su%e"viso" to ensu"e safe #o"$in' envi"onment %"io" to an& fu"the" #o"$s #ithin the %it/ t"ench. ;.6 *%en t"ench #i!! be %"o%e"!& ba""icaded.
