METHOD STATEMENT MANUAL

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Rev. Date :

Issue No. : 1

PIPELAYING WORK

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OBJECTIVE The purpose of this method statement is to describe the pipe laying works for Package MSG 1,MSG 2, MSG 3, MSG 4 and MSG 5. This method shall be read in conjunction with the following documents. i) Construction Drawings ii) Specification iii) Traffic signboard drawings

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TRAFFIC MANAGEMENT DRAWINGS WORKS PREPARATION

Contractor, PAAB & SAJH shall conduct a Pre-job meeting prior to the commencement of the installation to ensure that all parties involved are well informed of the work process. Approval should be obtained from the relevant authorities such as Jabatan Kerja Raya and Presint Ventures Sdn Bhd before pipe laying can be carried out All material such as pipe, fitting, valve should be submitted to SAJH for approval Ensure that the pipe route for the trench shall be pegged out accurately as construction drawings and to determine the existing trees or services involve along the pipe route Pilot excavation shall be conducted to locate existing pipeline and any services that may interfere with the works

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METHOD OF CONSTRACTION This work shall consist of few scopes of works as stated below: Provide the Traffic Management Plan Pipe Trench Excavation and Pipe Laying
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METHOD STATEMENT MANUAL

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Welding for Mild Steel Pipe Back filling with suitable material, sand and crusher run as satisfactorily Communication Pipeline and Meter Stand

Traffic Control System This traffic control shall be conducted before the excavation works is carried out. All the signboard and safety equipment shall be ready and comply the requirements of the authorities and approved by S.O. Pipe Trench Excavation Before commented the excavation works Tar Macadam and similar road surfaces shall be broken out neatly along the trench line using diamond disc road cutter to keep the edges straight and vertical All trenches excavation and other work carried out within the limits of any road reserve shall be completed as rapidly as possible. Not more than half of the width of the carriageway shall be obstructed at one time unless a full diversion has been provided and approved by the relevant authorities. A minimum width of 4m for traffic lanes shall have to kept clear for traffic flow. Where trench are excavated in public roads, road shoulders and footpaths of congested areas necessitating carting spoil to distant tips, also employ suitable plant to ensure that the passage of traffic past the works is not impeded by the loading and unloading of spoil. Excavated materials shall not be left open for more than one day and all trenches on road verges shall not be left open for more than three days. The continuous support of the sides of the excavation from the time excavation is begun until refilling of the trench is completed to ensure that there is no disturbance of the adjacent road or road foundation and also provide barricades to fence off the works and approved road sign boards placed at regular intervals to ensure safety of the public and vehicles.

Pipe Laying Team The approximate of the pipe lengths: 155mm ND bellmouth AB-3P pipes = 2,090m 155mm ND bellmouth uPVC pipes = 8,073m Tapping and communication pipes = 1,082 unit

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The pipe laying team crew for each team consist of : Backhoe Dump Truck Rammer Compactor Water Pump Welding Machine Oxy Cutter Tools Foreman Welder Pipe layer General Worker - 1 no - 1 no - 1 no - 2 no - 1 no - 1 no - 1 set - 1 person - 1 person - 2 person - 3 person

Pipe Laying All pipe and fittings shall be laid into the lines and levels shown on the drawings or as otherwise directed by the S.O. The crane or excavator to use for handling the pipe into the trench, a recess shall formed in the trench foundation beneath to permit the sling to be withdrawn without damage to the coating and sheating Pipes and specials shall be placed in position singly and the order of laying pipes shall be subject to the approval of the Superintending Officer Pipes and fittings to be embedded in concrete shall be held firmly in position and protected from while the concrete is being placed. should any pipe become either partially or wholly clogged before final acceptance of the work, it shall be cleaned out or replaced After laying, the interior or pipes, specials and valves shall be carefully cleaned again to remove any dirt, stones or other matter that may entered during laying. Except when work is actually proceeding, all open ends of the pipes and specials in the trench shall be kept closed by means, to prevent the entry of dirt, stones and the like, but stopper shall allow the entry of water. Where it is necessary to cut pipes to provide closing length or for laying pipe specials or in the repair of damaged or chipped pipes, the cutting shall be neatly and accurately performed so as to leave the end of the pipe truly normal to the axis of the pipe.

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Welding of pipe Where the steel pipes are to be joined by welding it shall be by means of an internal and an external circumferential electric are weld at each joint. Before placing the pipes together, the portion of the sockets and spigots to be welded shall be cleaned. The spigot end shall then be placed in the socket and forced inside so that the spherical surfaces are in contact and that the gap between the pipes at the end of the spigot is nowhere greater than 1.5m. For longitudinally welded pipes, the longitudinal welds on adjacent pipes shall be at least 15 degrees out of line. Details of the socket and spigot welded joints are shown on the drawings. The annular space between the two welds shall be air tested. While this pressure is maintained for a minimum periods of ten minutes, the welds shall be examined carefully for leakage. Any defective welding shall be treated as directed by the SO. The tap holes shall then be sealed off with welding after each joint has been satisfactorily tested. The contractor shall provide all necessary gauges, pumps etc., for the air testing. After the SO has advised the contractor in writing that a welded joint has passed the air test the external sheathing shall be completed to ensure continuity of protection along the pipeline. Bare metal shall be thoroughly cleaned and primer has set the sheathing shall be completed by running hot bitumen into a metal mould placed over the joint and overlapping by sheathing by 75mm on either side of the joint.

Sand Filling Approved sand backfilling to trench excavation shall be provided as shown in drawing or as directed by the SO. The sand material shall be deposited in 150mm layer on both sides of the pipe simultaneously and thoroughly compacted and around the pipe working alternately on either side of the pipe until the trench has been filled up to the base course formation level. The sand filling material shall be compacted by a suitable plate vibrator to ready receive limestone crusher run as per specification. The limestone crusher run shall not exceeding 40mm size to original thickness or a minimum thickness of 300mm to be spread and compact including all the stop end.

Bituminous Prime Coat Descriptions

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This work shall consist of the careful and through clearing of the surface of a prepared and accepted road-base and the furnishing and application to the cleaned road base surface of bituminous printing material, all in accordance with the specification and the lines, dimensions and cross-section shown on the drawings and/or required by SC. Materials The bituminous priming material shall be approved cationic type of bitumen emulsion grade SS-IK. Prior to applying the prime coat, the road base shall have been shape and compacted in accordance of the specification. Notwithstanding any earlier approval of finished road base, any damage to or deterioration of the road base shall be made good to the satisfaction of the SC before prime coat is applied. Immediately before applying of bituminous prime coat, the full width on the surface to be treated shall be swept using a broom. If necessary, scraped using hand tools to remove all dirt, dust and other objectionable material, all to the satisfaction of the SC. Prime coat shall be distributed uniformly over the surface to be treated without streaking. The quantities applied shall not deviate by more than 10% from those prescribed. Areas with insufficient bituminous material shall be resprayed as necessary to make up the deficiency, all to the satisfaction of SC. The contractor shall maintain the prime coat, all to the satisfaction of the SC until the overlying binder course is constructed, which shall not be within 24 hours after the application of the bituminous priming material nor within such longer period as is required in the opinion of the SC for the prime coat to achieve maximum penetration of the road base and become fully cured.

Asphaltic Concrete Description The work shall consist of furnishing, placing, shaping and compacting asphaltic concrete binder course/ wearing course on a prepared and accepted bituminous or bitumen primed pavement course and shall include the careful and through cleaning of surfaces which are to be covered without receiving a bituminous tact coat. The work shall be carried out all in accordance with the
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METHOD STATEMENT MANUAL

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specification and the lines, levels, grades, dimensions andcross-sections on the shown on the drawings and/or as required by the SC. Materials Asphaltic Concrete used as Binder Course and Wearing Course shall make of composition of mixtures from course aggregate, fine aggregate and bitumen by the manufacturer. The mix design for Asphaltic Concrete shall be submit to SC for approval prior to carry out site works. Construction Method Asphaltic concrete paving work shall only be carried out in dry weather when the surfaced to be covered is dry, or if so specified has received a bituminous tack coat which shall have achieved a satisfactory degree of tackiness, all to the satisfactions of the SC. All laying and finishing work shall be carried out during daylight hours, unless the contractor has provided suitable flood-lighting for the job site, to the satisfaction of the SC. The SC may order the discontinuation of work on account of adverse weather, unsatisfactory conditions as he shall consider detrimental of the work. Prior to constructing of asphaltic concrete pavement layer, the surface to be covered shall have been prepared in accordance with the specification. Any damage to or determeration of it shall be made good before asphaltic concrete paving work is commenced. Asphaltic concrete shall be transport from mixing plant to the site of the paving works in loads of not less than 5 tones using tip-trucks, asphaltic concrete is to be hand laid, it shall be discharge directly into , from the tip-trucks. All the works should be supervised carefully from loading, hauling and unloading operations to prevent segregation of the mix. During transportation, the asphaltic concrete shall be protected from contamination by water, dust, dirt and other deleterious materials. As far as is practicable, laying shall be carried out by hand methods using rakes, lutes and other hand tools, all to the satisfaction of the SC. All laying bitomious mix shall be such that after compaction by plate compactor the specific course or layer thickness and surface texture free from indentations, ridges, tear marks or other irregularities. And to prevent segregation of the mix. Where longitudinal or transverse joint are required in a layer of bituminous mix under construction the material first laid and compacted shall be cut back to a vertical face for the full thickness of
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the layer on a line satisfactory to the SC before the adjacent area is paved. Construction joints in layer of bituminous mix shall be offset from those in any immediately underlying bituminous layer at least 100mm for longitudinal joints and at least 0.5metre, where possible, for transverse joints. For each layer of asphaltic concrete compaction by plate compactor shall be commence as soon as the material will support the roller without undue displacement, nevertheless the temperature of asphaltic concrete at the commencement of rolling shall be not less than 1100C Proper compaction shall be carried out using vibrating plate compactors, hand tapers or other suitable means, all to the satisfactions of the SC. Initial plate compactor shall be carried out with an operating weight of not less than 3 tones. In all cases, compaction shall be carried out in such a manner that each section received equal compaction effort, all to satisfaction of the SC. Asphaltic concrete binder and wearing courses shall be finished in near workmanlike manner; their width shall be everywhere as specified or shown on the drawings on both side of the center-line. The average thickness over any 100metre length shall be not less than the required thickness minus 5min.

Bituminous Tack Coat Description This work shall consist of the careful and thorough cleaning of the surface of a prepared and accepted asphaltic concrete binder course, and the furnishing and application to the cleaned surface of a bituminous pavement course, all in accordance with the lines, dimensions and cross-sections shown on the drawings and/or required by the SC. Materials Bituminous tack coat material shall be of approved cationic type bitumen emulsion of grade RS-IK. Construction Method

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Bituminous tack coat shall only be applied as far in advance of the construction of the overlying wearing course as is necessary to achieve a satisfaction degree of thickness before the overlying material is placed all to the satisfaction of the SC. Prior to applying bituminous tack coat the surface to be treated shall have been prepared in accordance with the appropriate sections of the specification. Any damage to it or deterioration of it shall be made good before tack coat is applied. Immediately prior to applying bituminous tack coat, the full width of the surface to be treated shall be swept using a broom, and if necessary, scraped using hand tools, to remove all dirt, dust and other objectionable materials all to the satisfaction of the SC. Tack coat shall be distributed uniformly over the surface to be treated without streaking the quantities applied shall not deviate by more than 10% from those prescribed. Areas with bituminous material in excess of these limits shall have excess removed at the contractors expense and areas with insufficient bituminous material shall be replayed as necessary to make good the deficiency all the satisfaction of the SC. The surface of structures, road furniture and trees adjacent to the areas being sprayed shall be protected in such manner as to prevent their being spattered or marred by bituminous material shall not be discharged into road drains, gutters etc.

Reinstatement Works

Reinstatement of the road pavement and road reserved will be restored to the approval of SO and the requirement of relevant authorities. Contractor to remove and replanting shrubs and trees affected for pipe alignment which inside R.O.W as of requirement by local authorities. Existing Slope protection (e.g Turfing and retaining wall) which are located inside the R.O.W will be rectified as authorities requirement. Contractor to arrange before and after the join inspection between local authorities, Syarikat Air Johor and Present Venture Sdn.Bhd. And submit the photographs to all parties as their reference the condition of road pavement and road reserve before and after laying pipes.

METHOD STATEMENT MANUAL

Rev. Date :

Issue No. : 1