Mss-Method Statements
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mitendra singhMss-Method Statements
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mitendra singhFORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 1 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
DOCUMENT NAME
QUALITY INTEGRATED MANAGEMENT SYSTEM PROCEDURE
CLIENT BY
KAMOA COPPER S.A.
ENGINEERING PROCUREMENT CONSTRUCTION
MANAGEMENT
DRA Global Limited
PRINCIPAL CONTRACT FOR BILL OF QUANTITIES
RIDER LEVETT BUCKNALL
CONTRACTOR BY
MINING SERVICES & SUPPLIES S.A.S.
PROJECT NAME
KAMOA KAKULA BACKFILL UPGRADE PROJECT
CIVIL AND EARTHWORKS CONSTRUCTION
PLANT AND PASTE PIPELINE
RFT NUMBER
KMC-KKP-22-CC201
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Property of MSS – Approved (Controlled document in Document Repository)
FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 2 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
LOCATION
KAMOA-KAKULA, DR. CONGO
INDEX
SR.N PAGE
DESCRIPTION
O NOS.
0. COVER PAGE 1 001 - 001
0. INDEX 002 - 003
1. HEALTH, SAFETY & ENVIRONMENTAL 004 - 005
2. METHOD STATEMENT FOR SURVEYING WORK 006 - 007
3. METHOD STATEMENT FOR EXCAVATION AND BACK FILLING WITH ANTI-TERMITE TREATMENT 008 - 016
METHOD STATEMENT FOR RCC WORK - ( SHUTTERING, REINFORCEMENT & CONCRETING WORKS
4. 017 - 082
)
5. METHOD STATEMENT FOR MASONRY WORKS 083 - 096
6. METHOD STATEMENT FOR INTERNAL PLASTERING WORK 097 - 102
7. METHOD STATEMENT FOR EXTERNAL PLASTERING WORK 103 - 110
8. METHOD STATEMENT FOR FALSE CEILING GYPSUM WORK 111 - 114
9. METHOD STATEMENT FOR INTERNAL PAINTNG WORK 115 - 119
10. METHOD STATEMENT FOR EXTERNAL PAINTNG WORK 120 -124
11. METHOD STATEMENT FOR TILING, SKIRTING, TOILET DADO & KITCHEN PLATFORM WORK 125 - 135
12. METHOD STATEMENT FOR DOORS & FRAMES AND WINDOW FRAMES 136 - 142
13. METHOD STATEMENT FOR FALSE CEILING INSULATION 143 - 146
14. METHOD STATEMENT FOR ROOFING SHEETING / CLADDING 147 - 151
15. METHOD STATEMENT FOR PLUMBING AND DRAINAGE WORK 152 - 168
16 METHOD STATEMENT FOR CONDUTING 169 - 171
17. METHOD STATEMENT FOR INTERNAL WIRING AND TESTING 172 - 173
18. METHOD STATEMENT FOR LIGHTINING FICTURES AND TESTING 174 - 175
19. METHOD STATEMENT FOR SCREED CONCRETE 176 - 178
20. METHOD STATEMENT FOR FABRICATION & INSTALLATION WORK 179 - 192
21. METHOD STATEMENTFOR PAVING / FLOORING 193 - 197
22. METHOD STATEMENT FOR SURFACE PREPARATION AND COATING PROCEDURE 198 - 205
23. WELDING PROCEDURE QUALIFICATION & SCHEDULE 206 - 217
24. METHOD STATEMENT FOR WATERPROOFING WORK 218 - 234
25. APPLICATION PROCEDURE FOR NON- SHRINK GROUT FOR STRUCTURAL 235 - 240
METHOD STATEMENT FOR HDPE PIPE WORK PROCEDURE FOR INSTALLATION, WELDING AND
26. 241 - 263
TESTING
METHOD STATEMENT FOR UPVC PIPE WORK PROCEDURE FOR INSTALLATION, WELDING AND
27. 264 - 290
TESTING
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 3 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
28. METHOD STATEMENT FOR JOINARY WORK 291 - 294
METHOD STATEMENT FOR FINISHING SLAB CONCRETING USING NON-METALLIC FLOOR HARDNER
29. 295 - 296
& POWER TROWEL MACHINE
30. METHOD STATEMENT FOR BREAKING EXCESS CONCRETE 297 - 298
31. METHOD STATEMENT FOR HONEYCOMB CONTROL & PREVENTION IN CONCRETE SURFACE 299 - 301
32. HONEYCOMB/ VOID RECTIFICATION IN CONCRETE SURFACE 302 - 305
33. METHOD STATEMENT FOR GLASS PARTITION WORKS 306 - 308
34. METHOD STATEMENT FOR DOOR FRAMES & SHUTTERS 309 - 314
35. METHOD STATEMENT FOR SANITARY WARES, FITTINGS & ACCESSORIES INSTALLATION 315 - 318
36. METHOD STATEMENT FOR METAL DOOR INSTALLATION 319 - 324
37. METHOD STATEMENT FOR EPOXY RESIN COATING WORKS FOR FLOOR 325 - 332
38. METHOD STATEMENT FOR DRYWALL INSTALLATION FOR GYPSUM BONDS 333 - 338
39. METHOD STATEMENT FOR FIBER OPTIC INSTALLATION 339 - 352
40. METHOD STATEMENT FOR WATER HEATER INSTALLATION 353 - 359
41. METHOD STATEMENT FOR COPPER WATER PIPING HOT & COLD INSTALLATION 360 - 370
42. METHOD STATEMENT FOR SPLIT AC INSTALLATION 371 - 380
43. METHOD STATEMENT FOR FIRE PROTECTION EQUIPMENT INSTALLATION 381 - 391
44. METHOD STATEMENT FOR HVAC DUCT & ACCESSORIES INSTALLATION 392 - 400
45. METHOD STATEMENT FOR INSTALLATION OF CABLE TRAYS 401 - 415
METHOD STATEMENT FOR INSTALLATION & TESTING OF EARTHING, BONDING & LIGHTNING
46. 415 - 427
PROTECTION
47. METHOD STATEMENT FOR FALSE CEILING WORKS (GYPSUM BOARD AND TILE CEILING) 426 - 431
48. METHOD STATEMENT OF POTABLE WATER/FIRE WATER NETWORK INSTALLATION 432 - 452
49. METHOD STATEMENT OF LV CABLES AND WIRES INSTALLATION 453 - 461
50. METHOD STATEMENT FOR SMDB, DB & FEEDER PILLAR INSTALLATION AND TESTING 462 - 472
51. METHOD STATEMENT FOR BUILDING MANAGEMENT SYSTEM 473 - 491
52. METHOD STATEMENT FOR FUEL TANK INSTALLATION 492 - 502
53. METHOD STATEMENT FOR GRP INSTALLATION 503 - 526
54. METHOD STATEMENT FOR BOLT TIGHTENING 527 - 534
55. METHOD STATEMENT FOR FM 200 FIRE SUPPRESSION SYSTEM 535 - 549
56. METHOD STATEMENT FOR MICC CABLES 550 - 557
57. METHOD STATEMENT FOR IRRIGATION SYSTEM 558 - 581
58. METHOD STATEMENT FOR CURTAIN WALL INSTALLATION 582 - 590
59. METHOD STATEMENT FOR CENTRAL BATTERY SYSTEM INSTALLATION (CBS) 591 - 598
60. METHOD STATEMENT FOR BUS DUCT INSTALLATION 599 - 613
61. METHOD STATEMENT FOR CCTV INSTALLATION 614 -624
62. METHOD STATEMENT FOR SUMP PUMP INSTALLATION 625 - 632
63. METHOD STATEMENT FOR TRANSFORMER INSTALLATION 633 - 644
64. METHOD STATEMENT FOR STANDPIPES, SPRINKLER PIPES & ACCESSORIES INSTALLATION 645 - 668
65. METHOD STATEMENT FOR STORM DRAINAGE 669 - 673
66. METHOD STATEMENT FOR INSTALLATION OF ELECTRICAL CONDUITS & BOXES 674 - 687
67. METHOD STATEMENT FOR MANHOLE CHAMBERS 688 - 695
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 4 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
68. METHOD STATEMENT FOR ELV (EXTRA LOW VOLTAGE) SYSTEM 696 - 707
69. METHOD STATEMENT FOR WATERPROOFING 708 - 732
70. METHOD STATEMENT FOR ANTI CARBONATION COATING 733 - 744
71. METHOD STATEMENT FOR FALSE CEILING WORKS (WOODEN) 745 - 748
72. METHOD STATEMENT FOR WATERSTOP INSTALLATION 749 - 759
END PAGE 760
GENERAL NOTE FOR
HEALTH SAFETY & ENVIRONMENTAL
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Property of MSS – Approved (Controlled document in Document Repository)
FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 5 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
SR. EFFECTIVE REV. MSS MANAGER MSS PROJECT CLIENT
CLIENT QA/QC
NO. DATE NO. QA/QC MANAGER SUPERVISOR
HEALTH SAFETY & ENVIRONMENTAL
1. Health & Safety
All employees will wear PPE. This includes Safety harness, overalls, safety boots and/or
gumboots with spats, hardhats, gloves, safety glasses and ear protection.
Employees to have completed working at heights training.
Employees to be hook up at all times.
All plant will be inspected on arrival on site for safety and environmental compliance and a
permit will be issued.
All plant will be checked daily and records filed with WBHO Safety Department.
All activities will be covered by individual risk assessment and safe work procedure which will be
presented to the labour carrying out the activity in DSTI’s and toolbox talks.
All scaffolding to be erected and dismantled as per WBHO Safety Plan.
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 6 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
All scaffolding to be erected by trained and appointed scaffold erectors.
All scaffolding to be inspected by trained and appointed scaffold inspector.
2. Environmental
Hazardous substances will be stored on site as indicated in the Environmental Method
Statement on the Handling, Storage and Management of Hazardous Substances. MSDS will be
available for appropriate chemicals/fuels stored.
All waste materials will be disposed of as indicated in the Environmental Method Statement on
Waste Management
Toilet and hand wash facilities will be supplied by WBHO as indicated in the Environmental
Method Statement on Site Establishment.
3. Records: Records will be recorded / submitted as per approved WBHO Quality Assurance plan.
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 7 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
METHOD STATEMENT
FOR
SURVEYING WORK
SR. EFFECTIVE REV. MSS MANAGER MSS PROJECT CLIENT
CLIENT QA/QC
NO. DATE NO. QA/QC MANAGER SUPERVISOR
SURVEYING WORK
1. Scope:
The scope includes the guidelines to be adopted for setting out and surveying works.
2. Reference Documents:
- BOQ / CONTRACT TENDER DOCUMENT
3. Equipment’s:
Calibrated auto-level, total station / theodolite and other appropriate survey equipments and
accessories.
4. Procedure:
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Property of MSS – Approved (Controlled document in Document Repository)
FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 8 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
1. Prior to use, ensure that all survey equipment’s (including hire equipments) have valid
calibration certificates.
2. Take over base co-ordinates furnished by clients / consultants and set up bench mark
datum.
3. Establish 2 station points (having specific Northing and Easting) at accessible locations
away from periphery of the building to be constructed. Ensure that bench mark shall
remain undisturbed till the completion of project.
4. Construct masonry pillars for the established permanent bench marks with embedded
steel plates at top. Plaster and finish the top surface neatly.
5. Drive 20 mm dia. rebar’s to at least 1.50 m depth all around the pillars and barricade the
pillars so as to protect he pillars from displacement.
6. Recheck the benchmark co-ordinates and put paint, punch marks on top.
7. Establish control pillars for individual structures as above with reference to benchmarks.
8. Run the traverse on all sides of structure and establish set out stations on grid lines.
9. Mark grid lines with reference to temporary benchmarks in both X and Y direction with
paint.
10. Plot detail survey plan showing site boundary, all reference points / pillar locations in
Auto-cad.
11. Superimpose building points given in architectural points over the plotted survey plan.
12. Refer this auto-cad drawing transfer centre line and out-lines points of walls, columns and
footings on the PCC.
13. Also transfer reduced levels from temporary bench mark for such at raft top, footing, tie-
beams etc.
5. Records :
1. Joint measurement and records surveying and levelling works.
2. Any other records as per contract requirements.
6. Reference Documents :
7. ITP Reference No :
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 9 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
METHOD STATEMENT
FOR
EXCAVATION & BACK FILLING
SR. EFFECTIVE REV. MSS MANAGER MSS PROJECT CLIENT
CLIENT QA/QC
NO. DATE NO. QA/QC MANAGER SUPERVISOR
EXCAVATION AND BACKFILLING
Raw Materials Used, Inspection and Acceptance Criteria
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 10 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
A) Materials used for backfilling:
1) Soil:
Soil for backfilling shall be freshly excavated, free from vegetation, boulders, silt and clay. Soil can
be either hard or soft.
NOTES:
1) All backfill material other than rubble shall be free from roots, grass and rubbish. It shall be
reasonably well graded and of maximum size 80 mm. All lumps and clods of size larger than 80
mm shall be broken down using wooden mallet.
2) Material brought from outside sources shall be approved by Quality Engineer at the place of
source and shall be visually checked each time during its delivery and unloading at site throughout
the period of backfilling work.
3) Backfill material shall be tested in laboratory at time of approval from source.
4) Change in source of materials shall be avoided. If unavoidable, the new sample and the source
shall be again approved by Quality Engineer before actual commencement of supply of materials
at site from fresh sources.
5) All backfill material shall be tested in laboratory once at the time of approval from source.
B) Water:
By mere observation, water should be clean and free from dirt and organic matter. Waste (treated)
water from STP can be considered suitable for compaction of backfill material.
Guidelines for Inspection of Backfill Material:
(Testing shall be done in laboratory only once at the time of approval of source)
Sr. No Description Mode of Inspection Acceptance Criteria
A Murum
1 Field Density Lab Test Not less than 90% of Max Dry Density
2 Plasticity Index Lab Test Not greater than 10
Standard Proctor Density
As per SANS
3 or Lab Test
Modified Proctor Density
4 Maximum Dry Density Lab Test As per lab test
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 11 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
5 OMC Lab Test As per lab test
E) Storage of Raw Material:
a) Soil for backfilling:
1) Excavated materials which in the opinion of Client and contractor are useful shall be stacked in
regular heaps, bunds with regular slopes. Such stacking shall be done within the lead (50 m or as
specified).
2) Stacks of soil shall be properly levelled for providing natural drainage.
3) All softer material shall be laid along the centre of heaps. The harder and more weather-resisting
materials shall be stacked so as to form the casing on the sides and the top of heaps of softer
material.
4) Soft and hard rock shall be stacked separately.
5) Murum, Sand and Rubble brought from outside shall be stacked separately in regular heaps of
height not more than 1.5m. Stacking shall be done as near to the place of filling as possible to
avoid excess lead. Berm width shall not be less than 0.8m.
6) For borrowed material, stacking shall be done truck-load wise all along the edge of excavated pits.
Material shall not be stacked against an existing wall.
7) Toe boards shall be provided to prevent stacked material from falling back into the excavated pits
F) Equipment and Tools:
a) Excavation and backfilling Equipment’s:
JCB
Pokhlain
Jack hammers
Dumpers
Concrete cutter (If required)
Surface compactor
Tandom roller
Vibratory roller
Dewatering pumps of suitable capacity
Pressure pump for spraying anti-termite treatment solution
Screeder
Vibratory Roller
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 12 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
b) Surveying Equipment’s:
Theodolite
Whole station equipment
Auto level
Levelling staff
Spirit Level
Right Angles
Paint & Brushes
c) Tools:
Crowbars
Pick axes
Spades
Wedges
Hammer
Line dori (50m)
Measuring tape (50m)
d) Temporary Facilities:
Platforms
Walkways
Shoring and strutting material (if required)
Night lamps
Procedures for Excavation and Backfilling works
Pre Excavation Procedures:
Setting out:
1) It shall be ensured that drawing indicating setting out points is available on site. Also necessary
surveying equipment as mentioned shall be available on site in good operational condition.
2) Setting out work shall be carried out using Theodolite or whole station Instrument. Setting out
of centre lines shall be done correctly as per drawing and masonry or concrete pillars shall be
erected at suitable points to serve as reference bench marks (or setting of wooden railings
around periphery of the building). Levels of reference bench marks shall be with respect to a
Permanent Bench Mark, which shall be made to draw excavation profile. All marking on these
shall be painted red and well preserved.
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 13 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
3) All excavation levels shall be determined from the reference bench marks and got approved
from Client before actual excavation work starts.
4) Client shall check and approve in writing the entire setting out profile, before which no
excavation work shall commence.
Excavation:
1) It shall be ensured that all necessary equipment, tools, instruments, material and consumables
including temporary facilities like platform, walkways etc. as mentioned are available at site.
2) All skilled / unskilled manpower along with supervisory personnel for carrying out work shall
have sufficient experience on similar works.
3) Excavation drawings shall clearly indicate in plan (preferably by dotted line) the part of soil to
be excavated and also levels to which excavation needs to be carried out.
4) For the purpose of understanding terminology used for soil to be excavated, soil shall be
classified in accordance with SANS code as under:
a) Ordinary soils:
These shall include all kinds of soils containing sand, silt, hard and soft laterite, shingles, gravel, clay,
loam, ash, etc. which can generally be excavated by spades, pick axes and shovels.
Removal of the same shall be done by mechanical excavators, shovels, draglines etc.
b) Soft and Decomposed rock:
This shall include rock, boulders, chalk, slate, laterite and all other materials which does not need
blasting and can be removed with picks, hammers, crow bars, wedges and pneumatic breaking
equipment like Jack Hammers.
c) Hard Rock:
This shall include all rock, occurring in large continuous masses, which cannot be removed except by
blasting. Boulders of rock occurring in such sizes and not classified under (a) and (b) above shall also
be classified as hard rock. Excavation in reinforced cement Concrete Works shall be treated as
excavation in hard rock.
During Excavation Procedures:
1) The excavation shall be done to correct lines, dimensions and levels as per drawing. Adequate
side slopes shall be maintained during excavation of loose soil to prevent soil from sides of
excavated pits from falling back into the pits.
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 14 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
2) Wherever required, proper shoring and strutting shall be provided to maintain and prevent sides
of excavations from collapsing.
3) No heavy equipment shall be allowed within 4m from edge of excavation or within a distance
equal to depth of excavation, whichever is less.
4) Excavated materials shall not be deposited within 1.5 m from edge of the excavation.
5) Any material obtained from the excavation which in the opinion of the Site Engineer is useful,
shall be stacked separately in regular stacks as directed by client / contractor engineer. Any
excavated material, which is not suitable for backfilling shall be carted away from the work place
as per directions of Site Engineer.
6) Planks placed over trenches for crossing shall not be slippery and of width not less than 75 mm
wide.
7) Necessary barricades shall be erected and maintained around excavated areas. Also warning
lamps at
Night shall be provided to ensure safety.
8) Pits shall not be excavated to final founding level, if concreting work is not to be carried out
immediately. Last 15 cm shall be excavated prior to providing blinding layer with lean concrete
(PCC). PCC shall be of proportion 1:2:4 or as specified by Consultant.
9) If by mistake, excavation is carried out below the level mentioned on the drawing, the same shall
be made up to correct level by filling with concrete.
10) If any bottom of excavation is left exposed and is deleteriously affected by atmosphere or water,
it shall be dewatered and excavated to sound base. Base of excavation shall then be filled up to
the required level with lean concrete. (Grade M-15 or as specified by Consultant)
11) Removal of buried piping, cables or any other underground services shall not be done without
prior permission of Client and all measures shall be taken to protect such lines till their removal.
12) Adequate precautions as per Consultant’s advice shall be taken to ensure that the excavation
operations do not damage the adjoining structures or dislocate underground services.
13) Any trees coming in the alignment of the excavation shall be cut after obtaining prior approval of
concerned authorities and any specific requirement laid out by them shall be complied with. Cut
trees shall then be removed from site as per instruction of Site Engineer.
14) Roots of trees not coming in the portion of excavation pits but whose removal is essential shall
be removed and hollows shall be filled up during backfilling.
15) Suitable drainage arrangements shall be provided to prevent surface water entering excavated
pits. Water within the pits shall be bailed out or dewatering shall be carried out using pumps of
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 15 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
adequate capacity to keep excavations free of water. Water removed shall be disposed off, away
from the excavated area.
16) Where water table is high, lowering of water table shall be carried out by well point system so
that general water table is below excavation level.
17) Excavation in rock shall be carried out either by chiselling with pneumatic drills or by blasting.
Chiselling shall be carried out to obtain correct slopes, shape and pattern of excavation pits as
per drawings.
18) Blasting shall be resorted to when excavation is to be done in hard rock, when chiselling
becomes uneconomical. Blasting shall be carried out by the licensed blaster. License from
statutory bodies shall be obtained prior to undertaking of blasting work.
19) Blasting shall be controlled blasting unless specified otherwise. Controlling shall be done by
covering portion of rock to blasted with steel plates or woven mesh of wire ropes, meshed at
200 x 200 mm spacing and then loaded it with sand bags. Loading shall be adequate to prevent
rock pieces from blowing away.
20) Such blasting shall be preferably carried out during lunch time if the work is carried out within
the premises of existing office, factory or working place. Blasting operation shall not be carried
out during night time.
21) Following precaution shall be taken blasting operation:
Area within minimum distance of 150m from the region to be blasted shall be evacuated.
Boundaries of the area to be blasted shall be guarded by minimum 4 persons who in turn shall
wave red flags on the boundary to prevent entry of personnel during blasting operation. Signal
shall be given before and after blasting.
It shall be ensure that all charges have exploded by counting number of charges to fired and
actual number of shots heard.
Misfires, if any, shall be brought to the notice of Consultant / Project Manager and necessary
remedial measure shall be taken as per Consultant’s advice.
22) Depth, dimension and levels of excavated pits shall be approved and recorded by the client /
contractor Site Engineer in the field book with signature of concern persons. Nature of the soil
at the excavated pit bottom shall be examined by client Engineer. If there is doubt regarding
safe bearing capacity (SBC) of soil, Consultant’s opinion shall be taken and appropriate test shall
be carried out to determine safe bearing capacity of soil. Further excavation shall be carried out
in such cases, if the consultant advice to do so.
23) After approval from client, bed of the excavated pits shall be firmly consolidated and levelled by
watering and mechanized compacting. Compaction shall be carried out using surface vibrators in
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METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 16 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
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case of small pits and by roller if the area is large. Defective spot shall be dug and filled with
concrete.
24) Concrete foundation work shall start only after Site Engineer gives the permission to do so in
writing. Laying plain cement concrete shall be carried out after the compaction of sub base has
been carried out to the satisfaction of Site Engineer. However, it shall be ensured that base is in
moist condition before laying PCC. If necessary, base shall be saturated with water for not less
than 6 hrs. But not exceeding 20Hrs.
Post Excavation Procedures:
Anti-termite Treatment to sides of excavated pits:
1) Anti-termite treatment solution shall be prepared on site by mixing solution mentioned.
2) Anti-termite treatment in foundation shall start after site Engineer gives his permission to do so.
Treatment shall be complete with treatment of soil underneath the foundation as well as to the
sides of the excavated pits to form a total barrier between foundation and excavated pits.
3) It shall be ensured that soil surface to be treated is dry before the start of application of treatment.
In no case treatment shall be given during raining. Or when the soil is wet or sub-soil water level is
high.
4) Solution shall be sprayed on bottom of pits as also on sides of pits up to a height of 300 mm above
concrete foundation level shall be treated.
5) Solution shall be allowed to get absorbed in the soil and concreting shall not be allowed unless the
treated surface of soil is dry.
Anti-termite treatment during backfilling:
1) Anti-termite solution being highly poisonous as well as inflammable, utmost care shall be taken
during their handling. Wearing of hand gloves to avoid skin contact as also wearing of masks to
avoid inhalation is recommended.
2) During backfilling operation anti-termite treatment for backfill shall start when the backfill has
reached a level of 500 mm below ground level. Treatment shall be given for every layer of backfill
there above as under:
Chemical emulsion shall be sprayed around all buried concrete members / masonry (surface) after
each backfill layer is compacted.
While spraying, emulsion shall be directed towards concrete members / masonry surfaces.
Rodding shall be done close to members treated by inserting 12mm MS rods at 150mm c/c and
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about 300mm deep. Rods shall be moved backward and forward in a direction parallel to treated
surfaces to ensure proper penetration and mixing of chemical with the backfill soil.
Recommended dosage is 7.5 litres per sqm m of vertical area of concrete members / masonry
surfaces in contact with the soil. However, dosage prescribed by manufacturer shall be followed.
Anti-termite Treatment to plinth and external perimeter of building:
1) Treatment shall also be given over the entire plinth area prior to laying PCC. Recommended dosage
is 5 litres / sq. m of area to be treated.
2) Finally the earth around the external perimeter of building shall be treated in a similar way by
rodding to a depth of 300 mm. Rodding shall be carried out in a similar way as described above.
Recommended dosage is 1.75 litres per running meter of external wall.
Backfilling:
1) Backfilling work shall not start until client gives his approval to do so. Material used for backfilling
shall be any one or combination of soil types mentioned
2) Back filling shall be done in layers of thickness not exceeding 30 to 45cm depending on compaction
equipment and method (loose soil before compaction). The soil layer shall then be watered
adequately and compacted to minimum 90% to 95% of Standard Proctor Density for soil other
than sand and 85% in case of sand. Compaction shall be carried out at optimum moisture content
(OMC).Soil after compaction shall be free from pockets underneath.
3) After the compaction of final layer of soil, at least 3 cores shall be taken from the areas directed by
Site Engineer and the soil shall be tested in laboratory for the degree of compaction achieved.
Results shall be matched above.
4) If the soil is excessively wet, it shall be allowed to dry sufficiently before compaction.
(Approximately OMC should be maintained)
5) Compaction shall be done with suitable mechanical equipment such as plate vibrator, vibratory or
tendon roller, or 10 Tonnes Power Roller as suitable for the area to be compacted. In areas where
mechanized compaction cannot be done, hand compaction shall be resorted to as directed by the
Site Engineer. Overall compacted thickness of soil shall be as per drawing.
6) Over the compacted ground, rubble soling shall be done. Stones shall be hand packed as close as
possible and bedded firmly on broadest base. Void shall be filled with chips and small stones.
7) Backfilling around water retaining structures shall be done only after testing of structures against
leakage is done.
Records :
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Reference Documents :
ITP Reference No :
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METHOD STATEMENT FOR
RCC WORK (SCAFFOLDING DESIGN,
SHUTTERING, REINFORCEMENT &
CONCRETING WORKS
SR. EFFECTIVE REV. MSS MANAGER MSS PROJECT CLIENT
CLIENT QA/QC
NO. DATE NO. QA/QC MANAGER SUPERVISOR
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RCC WORK
RCC work can be divided into 3 parts:
Reinforcement Steel
Formwork
Procedures for Concreting
Reinforcement Steel
Scope
The requirement of deformed steel bars and wires for use as reinforcement in concrete is basically
categorized in the following three strengths.
Fe 415
Fe 500
Fe 550
Steel reinforcement and its requirement in concrete structure:
Steel reinforcements are used, generally, in the form of bars of circular cross section in concrete
structure. They are like a skeleton in human body. Plain concrete without steel or any other
reinforcement is strong in compression but weak in tension. Steel is one of the best forms of
reinforcements, to take care of those stresses and to strengthen concrete to bear all kinds of loads.
Bar-bending-schedule:
Bar-bending-schedule is the schedule of reinforcement bars prepared in advance before cutting and
bending of rebar. This schedule contains all details of size, shape and dimension of rebar to be cut.
Types of steel reinforcements used in a reinforced concrete structure:
Mild steel bars conforming to SANS and Cold-worked steel high strength deformed bars conforming to
SANS (grade Fe 415, grade Fe 500 and Fe 550, where 415, 500 and 550 indicate yield stresses or 0.2 %
proof stress in N/mm2) are commonly used. Grade Fe 415 is being used most commonly nowadays. This
has limited the use of plain mild steel bars because of higher yield stress and bond strength resulting in
saving of steel quantity. Some companies have brought thermo mechanically treated (TMT) and
corrosion resistant steel (CRS) bars with added features. Bars/wires range in diameter from 4 to 50 mm.
Cold-worked steel high strength deformed bars start from 8 mm diameter. For general house
constructions, bars of diameter 6 to 20 mm are used.
Specifications:
The reinforcement steel is generally available in three forms.
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1) Mild steel rounded bars of different grades
2) High strength deformed of different grades and types
3) Corrosion Resistant Steel
The structural requirements of reinforcing steel:
Reinforcing Steel has to satisfy some basic requirements to efficiently perform in concrete structures.
Durability of the reinforced concrete structures will greatly depend on the basic requirements. A few of
them are as given below:
Tensile strength
Bond strength
Ductility
Bendability
Weldability
Fatigue strength
Corrosion resistance
Fire resistance
Terminology:
Batch:
Any quantity of bars /wires of same size and grade whether in coils or bundles presented for
examination and test at one time.
Bundle:
Two or more coils or a number of lengths properly bound together.
Elongation:
The increase in length of a tensile test piece under stress. The elongation at fracture is
conventionally expressed as a percentage of the original gauge length of a standard test piece.
Longitudinal Rib:
A rib of uniform cross-section, parallel to the axis of the bar/wire (before cold-working, if any).
Nominal Diameter or Size:
The diameter of a plain round bar / wires having the same mass per metre length as the deformed
bar / wire. Nominal Perimeter of a Deformed Bar / Wire - 3.14 times the nominal diameter.
Nominal Mass:
The mass of the bar / wire of nominal diameter and of density 0.00785 kg/mm2 per metre run.
0.2 Percent Proof Stress:
The stress at which a non-proportional elongation equal to 0.2 percent of the original gauge length
takes place.
Tensile Strength:
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The maximum load reached in a tensile test divided by the effective cross-sectional area of the
gauge length portion of the test piece. Also termed as ultimate tensile stress.
Transverse Rib:
Any rib on the surface of a bar / wire other than a longitudinal rib.
Yield Stress:
Stress (that is, load per unit cross-sectional area) at which elongation first occurs in the test piece
without increasing the load during tensile test. In the case of steels with no such definite yield point,
proof stress shall be applicable
Table No. 1
Typical properties of Thermex Rebars N/mm 2 as compared to the minimum requirements specified in
the various codes:
Properties Fe415) Thermex Fe500 Thermex Grade 460 Thermex
400 500 B.S.4449 450
Yield strength 415 430 - 480 500 520-580 460 460
Min. N/m2
U.T.S Min. 485 500 - 590 545 590-660 506 520
N/mm2
A5 elongation 14.5 19 – 25 12 18 - 24 12 17
min %
Stress ratio min 1.10 1.15 – 1.25 1.08 1.15 – 1.05 – 1.10 1.12
yield 1.25
strength/ultimate
tensile strength
Carbon < 0.30 < 0.25 < 0.30 < 0.25 < 0.25 < 0.25
NOTES:
Thermex Thermo-Mechanical Treatment (T.M.T) bars produced by adopting quenching and
tempering patented technology are far superior for high performance RCC structures.
The tendency of pit propagation in T.M.T. 42 C.R.S. bars is comparatively less than high strength bars
produced without using alloying elements while rolling. Pit propagation is also observed to be more
on cold twisted deformed bars than T.M.T. 42 C.R.S. bars.
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It is observed that T.M.T. 42 C.R.S bars have a competitive edge over other rebar where corrosion
resistance is concerned.
Table No. 2
Physical Properties of Reinforcement steel as required by various standards:
Property Normal size of bar SANS
Fe415 Fe500 Fe550
Min. Ultimate tensile All sizes 10 % more than yield 8 % more than yield 6 % more than
strength (MPa) stress, min. 485 stress, min. 545 yield stress, min.
585
Min. Yield stress Up to 20 mm 415 500 550
(MPa) 20 to 40 mm 415 500 550
Min. Elongation (%) All sizes 14.50 12.00 8.00
Mandrel dia. For Bend Up to 22 mm 3d 4d 5d
Test Above 22 mm 4d 5d 6d
No cracks should be No cracks should be No cracks should
observed observed be observed
Mandrel dia. For Up to 10 mm 5d 5d 7d
ReBend Test Above 10 mm 7d 7d 8d
No cracks should be No cracks should be No cracks should
observed observed be observed
Table No. 3
Chemical properties of Reinforcement steel as per various standards:
Property ( % -Max) SANS CRS
Fe 415 Fe 500 Fe 550
Carbon 0.300 0.300 0.300 0.18
Sulphur 0.060 0.055 0.055 0.05
Phosphorous 0.060 0.055 0.050 0.12
Sulphur + 0.110 0.105 0.100 0.17
Phosphorous
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Silicon --- --- --- 0.45
Manganese --- --- --- ---
Corrosion --- --- --- 1.50
Resistant Elements
Procedure:
1) Material received at site should have ISI / ISO certification mark or the supplier should be pre -
approved from QA department after verification of physical and chemical properties as specified in IS
1786. Bars should be marked to identify categories.
2) For diameter up to 12 mm, One sample per diameter per supplier/manufacturer for every 60 Ton
must be tested in an independent/external laboratory. For diameter above 12 mm, One sample per
diameter per supplier/manufacturer for every 100 Ton must be tested in an independent/external
laboratory.
3) Proper equipment / jig should be available for straightening the coiled steel and mandrel for bending
and cutter machine for cutting steel bars.
4) Use of latest revisions of drawings and bar bending schedules should be done.
5) Bent bars of identical size, shape and type must be bundled together and labelled correctly before
placing.
6) Steel surface should be free from grease, oil, mud, mould oil, loose mill scales, excessive rust scales,
and loose concrete.
7) Binding wires must be bent inwards or loose ends cut so that they do not come in cover zone and/or
protrude out of concrete.
8) Beam-column junctions reinforcement steel bars should bunched or spaced properly to avoid
congestion.
9) Enough space between bars should be available to place and compact concrete.
10) Radius of bend given to dowel at construction joints must be as per drawing or as specified by
structural consultant.
11) For long duration of storage, bar must be protected by corrosion resistant passivator / converter
coat.
12) Bars of different types and diameters must be stored separately and clear identification between
tested and untested steel should be marked at site.
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13) Reinforcement bars received at site should be stored on hard concreted platform and clear above
the ground with the use of timber sleeper, concrete sleeper or any other means. Reinforcement should
be kept covered by tarpaulins or plastic sheets to avoid excessive corrosion and other contamination.
14) Cover blocks should be of non-corrosive material such as plastic or concrete/mortar but not wooden
or broken tile, broken bricks or stone. Especially PVC made cover spacers should be used in the works.
15) Binding wire should be 16 or 18 gauge conforming to SANS. It should be free from rust, oil, paint,
grease or any other deleterious material.
16) Splices should be provided as far as possible away from sections of maximum stress and must be
staggered.
17) Where more than one-half of the bars are spliced at a section or where splices are made at points of
maximum stress, special precaution should be taken, such as increasing the length of lap and / or using
spirals or closely spaced stirrup around the length of the splice. (Staggered laps) or as suggested by
structural consultant.
18) Horizontal distance between two parallel main reinforcing bars shall usually not less than the
greatest of the following:
The diameter of the bar if the diameters are equal,
The diameter of the larger bar if the diameters are unequal, and
5 mm more than the nominal maximum size of coarse aggregate.
19) Greater horizontal distance than the minimum specified in Clause no. 18 should be provided
wherever possible. However when needle vibrators are used, the horizontal distance between bars of a
group may be reduced to two-thirds the nominal maximum size of the coarse aggregate, provided that
sufficient space is left between groups of bars to enable the vibrator to be immersed.
20) Where there are two or more rows of bars, the bars shall be vertically in line and the minimum
vertical distance between the bars shall be 15 mm, two-thirds the nominal maximum size of aggregate
or the maximum size of bars, whichever is greater.
Tests to be carried out on Reinforced steel
A) Physical Tests
Rolling Margin
Tensile Test: - 0.2% proof stress, yield stress, elongation etc.
Bend and rebend test.
B) Chemical Tests.
Carbon
Sulphur
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Phosphorous
Sulphur + Phosphorous
Silicon
Manganese
Corrosion Resistant elements
Checklist before accepting consignment of steel:
Following check points should be considered before accepting the consignment of steel.
1) The type of steel i.e. mild steel/high strength deformed or twisted/corrosion resistant steel.
2) The grade of steel based on chemical and physical requirement.
3) The rolling margin.
4) The original steel certificate issued by steel supplier.
5) The physical and chemical properties in manufacturer’s test certificate.
6) Bend Rebend test at site.
Following check points should be checked after placing of steel:
1) The cutting and bending are in order.
2) Spacing between bars as per drawing
3) The effective depths, top and bottom cover in slab as per drawing.
4) Position of top steel bars in case of cantilever slabs.
5) Corrosion inhibiting layer applied over the steel bars if specified.
6) The lap length and hook length / angle of bars as per drawing.
7) The welding of bars as per drawing or as per standard details.
8) Deviation due to any reason is verified by design office.
Formwork
General:
Formwork is dye or mould used to shape the wet concrete until it sets and attains sufficient strength to
carry its own weight and retains its shape. There are various types of shuttering material used for
construction in India. Some of them are given below:
Conventional shuttering system
Mivan shuttering system
Formwork and False work (F& F)—Terminology:
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Formwork (Shuttering):
Mould to contain the wet concrete in the desired shape.
False work (staging, cantering):
Temporary structure used to support a permanent structure during erection and until it becomes
self supporting.
Scaffolding (Paranja):
Light structural “Framework” for easy access of workmen.
Striking (Stripping):
Scientific dismantling and removing formwork (pre-planned).
Sheeting (Sheathing):
Supporting membrane in contact with the wet concrete.
Joist (Batten):
Horizontal member supporting sheeting (slabs & beams).
Bearer (Runner):
Horizontal member supporting joists.
Prop cap:
Seating for bearer. (Axial load)
Prop:
Vertical member supporting bearer
Prop base:
Seating for prop( Punching shear).
Prop footing (Spreader)
Member transferring all loads on unyielding strata.
Wedge:
Packing piece used for correct levelling & easy striking of formwork.
Wailing or Waling:
Horizontal member resisting hydrostatic concrete load on sheeting (vertical walls)
Stud:
Vertical member resisting hydrostatic concrete loads on sheeting. (Walls).
Soldier:
Vertical supporting member cantilevered from previous concrete.
Yoke:
a) For columns - Horizontal frame support encircling formwork.
b) For slip form - Vertical frame support straddling inner & outer formwork.
Stop-end (Bulkhead):
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Vertical formwork to form a construction joint in concrete.
Back form:
Formwork to the top surface of a sloping slab
Bracings:
a) Horizontal - Member in 2 direction slenderness ratio of props.
b) Diagonal - Member transferring horizontal and wind loads through props.
Tie Bolt:
Interconnecting two opposite formworks to resist hydrostatic loads.
Riband:
Horizontal member laid flat to resist horizontal pressure from formwork.
Starter (Kicker):
Small height of wall or column cast along with the footing.
Shikanjas:
To hold the 2 opposite formwork or to hold the two right angle formwork.
Four way head:
To support to I-section beams below slab or beam bottom.
Tripod:
To keep prop in exact plumb & position.
Conventional Shuttering System:
Specification:
Following are the materials used for formwork shuttering work.
1) Props
Timber props
Adjustable Telescopic Steel Props
Timber Props:
Timber props shall be used only where height of structure is less than 2.4 meter
Timber props shall have uniform cross section throughout their length and shall be free of cracks,
bends, splits, and knots and warping. Any part of prop should not show signs of decay. Top and
bottom ends shall be sawed to true horizontal plane. Props with outer skin showing peeling and
rotting shall be rejected.
Cracks if present shall be restricted to 1.5mm in width, superficial not more than 1/3rd length of
prop and should not propagate till either end. Deviation from plumb, if any, shall be restricted to
L/300.
Comparatively smaller end of prop should be used as prop head.
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 29 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
Diameter of wooden prop should not be less than 75 mm.
Adjustable Telescopic Steel Props:
Steel props shall be telescopic and adjustable type. Diameter of outside and inside tube and weight
shall be as per manufacturer’s literature.
Generally outer prop is 50 NB (OD 60.3 mm) and inner prop is 40 NB (OD 48.3 mm) of 8 SWG (4mm
thick).
Outer prop shall be provided with a base plate of size 150 x 150 x 5 mm whereas inner prop may be
provided with top plate / fork head / U head.
Props shall be truly vertical with the maximum deviation in plumb as 1 in 600.
There should be minimum 6 threads above and below the sleeve. Prop nut shall be provided to
outer prop in such a way that it can be easily rotated through full height of sleeve. Locking pin (shear
pin) shall be of high tensile steel and of minimum 12mm diameter.
In addition to above props, some mini props (junior props) for supporting concrete members at
short heights shall also be procured as per the requirements.
Props must be braced in both the directions by tubes and double couplers at approximately 250 mm
above prop nuts when extended beyond 3.6 meters.
Load Carrying Capacity of props:
Long Props:
Height Self Axial Load
Prop
Closed Extended Closed Extended
0N 1.10 m 1.75 m 3500 kgs 3000 kgs
1N 1.50 m 2.75 m 3200 kgs 2300 kgs
2N 2.00 m 3.25 m 3000 kgs 2200 kgs
3N 2.00 m 3.75 m 2900 kgs 2000 kgs
4N 3.00 m 4.65 m 2300 kgs 1150 kgs
Mini Props (Junior Prop / light Duty Prop)
Outer diameter: 50.8 mm
Inner diameter : 42.2 mm
Height Self Axial Load
Closed Extended Closed Extended
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 30 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
2.00 m 3.20 m 1500 kgs 1000 kgs
2) Bracings and couplers for steel props:
Bracing pipe for props shall be generally 40 NB (OD 48.3 mm) tubes. Tubes shall be checked for
straightness. All couplers shall be checked at random for proper fitting over the pipes. They shall be
preferably galvanized. Tightening as well as removal shall be easy.
Adjustable Telescopic Steel Spans:
Steel spans shall be telescopic with inner and outer sections. Manufactured out of sheet, lattices of
10mm diameter bar, main bar 14mm diameter, bearing angle 75 x 75 x 10 mm, with 2 nos. of eye bolts
with additional angle stiffener welded to the sheet and bearing angle from inside.
Total load Permissible clear span for center line spacing (in mm)
including 180
Slab kg/sq.m. for 300 mm 450 mm 600 mm 800 mm 900 mm 1150 mm
Thickness shuttering & spacing spacing spacing spacing spacing spacing
live load
Kg/sq.m.
100 420 8050 6550 5690 5000 4650 4010
115 456 7800 6400 5510 4750 4470 3890
125 480 7570 6200 5330 4650 4340 3760
140 516 7310 5970 5160 4500 4190 3630
150 540 7110 5790 5000 4350 4090 3560
165 576 6880 5660 4870 4250 3960 3430
180 612 6730 5490 4750 4100 3890 3350
190 636 6550 5360 4620 4050 3780 3280
200 600 6400 5230 4520 3950 3680 3200
225 720 6150 5000 4340 3800 3530 3070
250 780 5920 4830 4140 3650 3380 2840
275 840 5660 4650 4010 3500 3280 2640
300 900 5490 4490 3730 3400 3150 2490
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 31 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
The Acrow spans should be used preferably for slabs only along the shorter span. Minimum overlap
between the trusses of the Acrow span should be 450 to 600mm with shear pin or packing. (Packing
should be preferably of M. S only) Acrow spans should not be used below beam bottom, staircase, and
waist slab and slopping roof / slab. Acrow span are to be checked thoroughly for their welding and
strength at both the end joints
H-Frame:
a) H-frame shall be provided when supporting height is beyond the range of opened length of steel
prop.
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
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METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 32 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
b) Vertical member of H-frame shall be of 40 NB (OD 48.3 mm) tube whereas horizontal member shall
be 32 NB (OD 42.4 mm) tubes. Bracings shall be 25 NB (OD 33.7 mm) tubes with ends pressed.
c) Vertical members shall be truly vertical and horizontal members shall be truly horizontal. Bracing
tubes shall be easy to fit and remove.
d) Bracing should be fixed with the H Frame with MS locking pins or MS Nails. Tying with coir or binding
wire is not permitted.
Scaffolding and its components:
a) Steel scaffold tubes shall be generally be of 40 NB (OD 48.3 mm) tubes. Scaffold tubes to be used as
initial standards shall be provided with base plates of size 150 x 150 x 5 mm thk. Base plate shall be
provided with two diagonally opposite holes. Weight of scaffold shall be as per manufacturer’s
specifications.
b) All fittings like swivel, right angle couplers, cup lock, wedge lock, brackets etc shall be galvanized and
painted.
c) Planks shall be minimum 40mm thick and 300 mm wide and without cracks. Length shall be sufficient
to have at least 300 mm overlaps over adjacent standards / ledgers.
Cup lock:
Cup lock is a system to connect four horizontal scaffold tubes. Four horizontals rest on a single vertical
prop. These four horizontals are covered with single cup like arrangement at the bottom of Cup lock.
Top of Cup lock is forming a cone at top to hold another vertical prop over it.
Note: - All steel formwork components including scaffolding tubes and fittings are manufactured in
accordance with SANS.
Formwork Materials:
Specifications, Periodic Inspection, design and Detailing
(Unless otherwise specified the material shall confirm to following standards)
1) Slab:
A) Sheathing
Ply : 12 mm thick marine ply with ISI mark
MS Plates : Size – 600 x 900 mm or 600 x 1250 mm.
Thickness of plate – 14 G to 16 G
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
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METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 33 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
Angle support for plates – ISA 35 x 35 x 5 mm / 30 x 30 x 3 mm / 25 x 25 x 3 mm
B) Sheathing Support (Primary)
Wooden Runners : 75 mm x 37.5 mm or 75 mm x 50 mm
C) Sheathing Support (Secondary)
Steel Spans : Supporting angle section – ISA 50 x 50 x 5 mm
Diameter of lacing MS bar – 10 mm dia
Wooden Runners : 75 x 50 mm
ISMC : Size as per design
D) Scaffolding
Steel Props : Outer diameter- 60.3 mm
Top plate – 75 x75 5 mm
Bottom plate – 150 x150 x6 mm
Pipe specification: IS: 2062 / IS: 8500 / IS: 1161
Wooden Props : 75 mm dia to 100 mm dia. (wooden props shall be used only where height of
structure
is less than 2.4 meter)
2) Beams:
Beams Bottom : Wooden planks of 25 mm thick& ply of 12 mm thick Marine ply of ISI mark.
Beam sides : 12 mm thick marine ply of ISI mark
Beam side horizontal runners – 75 x 37.5 or 75 x 50 mm
Beam side vertical supports – 75 x 50 mm
Beam side inclined struts – 75 mm x 50 mm or 75 mm x 75 mm
Tie bolts : 16 mm dia
3) Columns:
Column sides : 12 mm marine ply with ISI mark or MS plates with Soldiers
Column side vertical runner : 75 x 37.5 mm or 75 x 50 mm
Column side horizontal walers : 75 x 75 mm or ISMC
MS supports : MS props
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Page 34 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
4) Shear walls
Shear wall sides : 12 mm marine ply with ISI mark or MS plates with Soldiers
Shear wall vertical runner : 75 x 37.5 mm or 75 x 50 mm
Shear wall horizontal walers : 75 x 75 mm or ISMC or spans
Inclined / horizontal supports : Props
5) Footings
Footing side : 12 mm thick marine ply
Footing side runner : 75 x 50 mm
Footing side supports : MS Props
Periodic Inspection:
1) Props and Spans:
Form work Inspection Acceptance criteria Frequency of
material inspection
Props (steel) Condition of top plate Not bent At the time of
/ Prop head approval of material
Condition of base Not bent and properly secured and thereafter every
plate 5 repetitions
to prop
Min 12 mm dia
Locking pin No rust, in plumb and proper
Condition of outer & gauge through out can be
inner opening opened with ease
Props (wooden) Diameter Not less than 12 mm from At the time of
(wooden props designated dia approval of material
shall be used only Crack Not more than 1/3rd the length and thereafter every
where height of of the prop 5 repetitions
structure is less
Straightness Deviation from verticality not
than 2.4 meter)
more than 1:15
Condition Wood should be dry and hard
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FORMATE ID:
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METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 35 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
H frames Diameter of props As per manufacturer’s At the time of
bracing, gauge of specification and approved in approval of material
props, pins, base design and thereafter every
plates, dimensions & 5 repetitions
welding of joints.
Spans Welding Welding Welds to be proper At the time of
Bolts In place and operational approval of material
and thereafter every
Top / Bottom Not damaged & corroded
5 repetitions
members Not damaged & corroded
Top / Bottom plates Not bent
Top end plates Plates should move freely
Oiling
2) Slab Bottom
Form work Inspection Acceptance criteria Frequency of
material inspection
Ply Warpage Within acceptable limits Refer note below
visible
Surface
Rough surfaces should not
Delamination exceed 5% of area
No delamination should be
Edges observed
Should be straight &
undamaged
Runners Cross section Not less than 5 mm of the Refer note below
designed width and + 3 mm
for depth
Warpage Should not be more than 5
Cracks mm
Not allowed
Centering Plates Bends Not more than 5 mm Refer note below
with angle
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
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METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 36 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
Welds of stiffeners Should be proper
NOTES:
For New Formwork Material:
First inspection shall be done at the time receipt, second inspection after first 5 repetitions and
thereafter every 2 repetitions.
For Old Formwork Material:
First inspection shall be done at the time before first installation, thereafter every 2 repetitions.
General:
Before using all the wooden chavis / struts / falis and wailings etc. it must be ensured that they are
Randha (planer) finished so that no undulations come on RCC surface. Before using any new or old
shuttering material on site, contractor must get their material checked and certified from Quality
Assurance Department. The rejected material must be removed from site or stored separately.
Procedures:
A) Procedures to be followed before and during erecting formwork:
1) Sequence and mode of construction shall be pre decided to make optimum use of available
formwork.
2) All staging members (props) shall rest on compacted ground / continues wooden plank for the
construction of first slab. Where steel props are used they shall be braced in both directions using steel
tubes and couplers. In addition, cross bracing shall be provided as per design. Props shall be erected in
plumb.
3) Props shall rest on cleaned slab surface. Packing below props shall be avoided. For staircase, props
should be placed vertical and wedges should be provided to maintain verticality.
4) If pins provided by manufacturers are not used (if pins are lost or misplaced) then use of minimum 12
dia. tor steel pins shall be allowed.
5) Spans shall be erected as per correct spacing given in design and shuttering plates shall be placed
tightly abutting each other. Overlapping portion of open spans shall be tightened with the help of 2 nos.
of bolt. (16 mm dia) In no case, overlapping portion shall be smaller than 450 mm to 600mm or as
specified by manufacturers. Spans shall be supported only at ends and not in between.
6) Gaps (Gabadi) in formwork shall be restricted to 5% of area of slab. Gaps less than 5mm should be
sealed with masking tape or cement grease or equivalent with approved gap sealer / sealant. If gap
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
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PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 37 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
found more than 5mm, ply rib of required size or equivalent should be used. Ensure that ply and ply rib
is maintained at same line and level.
7) Independent scaffold shall be erected for fixed forms, reinforcement placing, concrete pour etc.
Adequate camber, if specified on drawing, shall be given to the erected formwork. (Camber at the beam
bottom shall be provided at the rate of 1mm per Running Meter of clear length.)
8) Bearer beam (of wood), shall be provided below beams at the prop location and they shall be
supported by props. The first support to beam shall be at 9” from RCC face. Beam side forms shall be
erected in plumb. Width of beam / shear walls shall be maintained using tie bolts / spacers of correct
diameter and length. Tie bolts shall be enclosed in PVC conduits with provision of removable plastic
cones with coil nut at ends. Inclined struts shall be erected as specified. Inclined strut can rest on bearer
beams or rest against laffas nailed on slab.
9) For footings, gap between side ply and PCC shall be sealed to make joints leak proof. For vertical
Members, a platform shall be erected not touching the side forms of vertical members for concrete
purpose.
10) For all concrete works, forms shall be kept above concrete level and inside of forms shall be marked
to indicate concrete level. For casting of columns, shear walls, lift pardi forms shall be kept projecting at
least 4” above concrete level so that next pour can be cast with a leak proof joint.
11) For all erected formwork, levels shall be checked with auto level. Fine correction shall be done in
level through adjustable steel props or adjustable prop heads. It is recommended that Site Engineer gets
mock up for walls and columns done and approves the same before starting of erection of formwork.
12) After placing of reinforcement in position, form surface shall be cleaned before concreting. Wooden
planks shall be provided over reinforcement as walkways to carry concrete to edged beams.
13) Scaffolding shall be either single scaffolding or double scaffolding as specified. Making of holes in
masonry should be avoided. For night work adequate lighting arrangement shall be provided.
14) For larger heights H frames shall be erected. The spacing of H frames shall generally be 2.0m to
2.5m. H-frames shall be connected by cross bracings and shall be provided with wooden planks / steel
gratings. H-Frame shall be used with stirrup heads and I / C section at top and proper packing should be
given to keep in position. Stirrup head should be opened only up to 60 % of its total length.
15) In no case part of column below beam bottom level should be cast along with slab / beam
concreting. All columns must be cast exactly up to beam bottom level. If small top portion of column
concreting is balance then the same should be concreted separately before taking up beam bottom
shuttering.
16) Spacing between wailers of sides of beams or columns should be within 9” to 12”.
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FORMATE ID:
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PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 38 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
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CONTRACTOR
NAME:
17) Any column with 2’-0” width or more should have tie-bolts at every yoke or 3 nos. bolts if vertical
chavi or angle is used.
18) For external columns and beams and crank beam of staircase, the alignment should be maintained
by using turn-buckle with wire rope only.
19) Checking of shuttering for slab Level marking should be transferred on column dowels at 2’ height,
line Dori should be fixed up and level of slab to be checked in three dimensions i.e. Length, Breath &
diagonally.
20) 25mm thick wooden dhar phalli shall be minimum 4” width all around slab gala, i.e. along periphery
of all internal beam sides so that one side will rest on internal beam side and other side on 3” X 3” chavis
having prop supports at 2’ – 0” c/c.
21) Small span slabs such as passage and toilets should have ‘Double Chavi’ (Two way chavi) supporting
systems, alternatively, if single chavi is used, it (each) should be supported on minimum 3 nos of props.
22) Shuttering for peripheral / external elevation beams
(a) 3” X 3” cantilever chavi should be provided through beam bottom @ 18” c/c. on which platform with
2 nos of 9” wide plank should be fixed all along the peripheral beams as a working platform.
b) 3” X 2” or 3” to 4” X 1 ½” or 2 ½” dia props pieces as racker support should be provided at 18” c/c
with this or continuous chavi support fixed on cantilever chavi.
c) 3” to 4” X 1 ½” wooden chance lafa will be provided connecting both beam sides at top to keep
straight and at required beam width.
23) Shikanjas should be fixed to each strut of beams at 18” c/c to the full area, which is to be concreted.
Shifting of shikanjas should not be permitted from one part to another part while concreting is in
progress for further areas.
24) To avoid leakages of slurry from shuttering at column / beam junctions, studs / struts from beam
sides should be taken down over the column side and should be gripped between two horizontal chavi,
on both sides of columns with bolts, nuts and clamps. No nailing is permitted. Refer Drawing for the
same as below.
25) Spacing between wailing of sides of beams or columns should be within 9” to 12”.
B) Procedures to be followed after erecting formwork:
1) Just prior to concreting all levels shall be rechecked. It shall be ensured that all fittings are tight. All
tolerances in form work shall fall within the limits mentioned in acceptance criteria.
2) During concreting, strict supervision shall be maintained on overall erected formwork. If any sinking
or displacement is observed during concreting, remedial measures shall be adopted immediately.
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NAME:
C) Deshuttering of formwork:
1) Deshuttering shall be done only with the prior approval of QA Department. Recommended
deshuttering periods are mentioned in table below. But this may vary depending on type of cement
being used, strength of concrete achieved on the day of deshuttering, type of form used etc.
2) Sequence of removal of props and other components shall be done as per instruction of QA
Department’s recommendation.
Deshuttering period after casting:
Formwork Deshuttering Period
16 – 24 hrs. (after checking final setting time of
Sides of column
concrete)
16 – 24 hrs. (after checking final setting time of
Sides of footings
concrete)
16 – 24 hrs. (after checking final setting time of
Sides of slab
concrete)
Slab supports
1) spanning up to 4.5 m 7 days
2) spanning over 4.5 m 14 days
Beam supports
1) spanning up to 6 m 14 days
2) spanning over 6 m 21 days
Cantilever 21 days
Acceptance Criteria for Erected Formwork:
Formwork Deshuttering Period
Dimension of column and beams in cross-
+12mm /-6mm
section
Footing dimensions in plan +50mm /-12mm
+0.02 times width of footing in the direction of
Eccentricity of footing
deviation but < 50mm.
Thickness of footing +0.05 times thickness of footing
Skin plate 1.5 mm
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Surface flatness for a single member
Span up to 1.5m +3mm /-3mm
1.5m to 3.0m +6mm /-6mm or span / 360 whichever is less
3.0m to 4.5m +9mm /-9mm
4.5m to 6.0m +12mm / -12mm
For every additional 6m +6mm / -6mm
Camber for beams and slabs 1 in 500 or as per RCC Consultant
+50mm / -50mm
Clamps for columns / beams
Formwork Drawing and Specification:
Table 1:
The following table shows the sizes of runners, vertical struts and inclined struts required for beam
formwork system and spacing of the same:
Size of Runners (mm)
Depth of No. of Size of Strut
75 X 37.5 100 X 37.5 75 X 50 50 X 75
Beam (mm) Runners (mm)
Spacing of Vertical / Inclined Strut (feet)
300 2 4.0 4.0 5.0 6.0
100 X 37.5
400 3 3.75 4.0 4.5 5.5
75 X 50
500 3 3.25 3.5 4.0 5.0
600 3 3.0 3.25 3.75 4.75
700 4 3.25 3.5 4.0 5.0 75 X 50
800 4 3.0 3.25 3.5 4.5
75 X 75
900 4 2.75 3.0 3.25 4.25
50 X 75
Beam side Formwork system:
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Beam Formwork System:
Refer Table 1 for sizes of different members
Details of Joinery at section B from above diagram:
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Page 42 of 864
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For Inner beam if beam side forms are greater than depth of beam:
Refer Table 1 for sizes of different members
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
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METHOD STATEMENTS
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PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
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Table 2:
The following table shows the sizes and spacing of Walers for Column formwork:
Size of Walers Length of
Centre to Centre Spacing of Walers
(mm) Column - L
75 X 75 1m 6” 6” 9” 9” 12” 12” 18” 18”
50 X 75 0.9 m 6” 12” 12” 18” 18” 24” --- ---
Vertical Runners
at 150 c/c for 12 0.8 m 6” 12” 18” 24” 24” --- --- ---
mm thick ply 0.7 m 6” 18” 24” 24” 24” --- --- ---
75 X 50 0.8 m 6” 6” 9” 9” 12” 12” 18” 18”
Vertical Runners 0.7 m 6” 12” 12” 18” 18” 24” --- ---
at 150 c/c for 12
mm thick ply 0.6 m 6” 12” 18” 24” 24” --- --- ---
0.5 m 6” 18” 24” 24” 24” --- --- ---
Table 3:
The following table shows the sizes and spacing of Form members for shear wall / lift pardi:
Height of ISA / ISMC from floor level
Size of Vertical Permissible Total No. of
Batten (mm) Overhang ISA / ISMC
1 2 3 4
75 X 37.5 2 feet 4 Ground 2’ 4’ 6.5’
75 X 50 2 feet 3 Ground 3’ 6.5’ ---
Formwork system for Column Starter:
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Column Formwork Elevation:
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Column Formwork System:
Plan at Intermediate Height for Columns:
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Alignment of Tie Rod in Column Formwork System:
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Elevation of ISMC / ISA alignment:
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Side Elevation of ISMC:
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Plan of Tie Rod Arrangement:
Typical Sketches and information of shuttering accessories
1) Cantering Sheet:
Wide range of Cantering Sheet/Floor Form are available that are manufactured with 2 mm sheets which
has been folded on all four side with suitable slot provided with stiffener. These are available in standard
sizes of:
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1) 900 x 600 mm 2) 1150 x 600 mm 3)800x 600 mm
2) Wall Form
Wall Form can be customized as per the specification of different projects. These are developed in
compliance with various industrial standards and are available in standard sizes such as:
Length: 1250 mm / 2500 mm
Width: 300, 350, 400, 450, 500, 600 mm
3) Flexible Panel
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Flexible Panel are widely used in various industries. These are available in various standard sizes and can
be customized a as per the specifications of project.
Sizes that can be availed are:
1250 x 500 mm,
1250 x 400mm
The Panel details are as follows:
Internal Corner Panel Size : 1250 x 150 x 150 mm
External Corner Panel Size : 1250 mm, 2500 mm long
Channel Soldier Size : 1250 x 100 mm, 2500 mm x 100 mm
Wall adjuster panel size : 1250x150mm/1250x225 mm/1250x350 mm
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4)Adjustable Props
Qualitatively superior, these are available in various types. Load bearing capacities have already been
highlighted in the form work section earlier.
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5) Wedge locks Systems
Designed and developed in accordance with the needs of the project, wide range of wedge lock systems
finds varied application in wide number of industries. These are qualitatively superior and can be
customized as per the specifications of projects.
Some features and specifications of the systems are:
Consist of vertical built of 40 mm NB
Heavy pipes with wedge housings welded at intervals of 500 mm / 100 mm in four directions at
right angles
Angular transom tubular ledger, tubular bracing having end fittings with locking wedges will fit into
the wedge housing with hammer
Maintenance free
Available in standard sizes
Upright / Vertical : 2 meter, 3 meter
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Tubular ledger 2 meter : 2.5 meter
Angular Tubular transom : 1.25 meters
6) Formwork System (For RCC Wall)
Formwork System for RCC Wall is available in customized as well as standard sizes and are of two types:
1. For simple RCC wall and
2. For round RCC Wall
For Simple RCC Wall:
Steel system shuttering
Standard panels made out of 45 x 30 x 5 mm / 45 x 45 x 5 mm
Angles suitably slotted with 50 mm
Intervals, skin plate of 2.5mm
Thick M.S. Sheet welded to the frame of wall form/channel soldier, internal corner panels
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7) H-Frame Scaffolding
Wide ranges of H-frame scaffoldings are manufactured `in accordance with the need of the projects.
These possess following features and specifications:
Welding frames of two vertical of 2 m (32 mm. N.B. Pipe)
Two horizontals of 1.22 m (25 mm N.B. Pipe)
Frames are inter-connected with bracing at an interval of either 2 m or 2.5 m through pins welded
on frame and locked suitably
8) Tube Scaffolding & Fittings
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Following types of scaffolding & fittings are available:
Double Coupler: For connecting 40 mm N.B tubes at a right angle.
Swivel Coupler: Used to connect 40 mm N.B. pipes at any angle.
Expanding Joint Pin: Suitable to connect 40 mm NB Pipes as Ledgers.
Fixed Base Plate: Suitable for 40 mm nominal bore steel tubes.
Adjustable Stirrup Head: Designed for fine adjustment of height between 80mm and 200 mm.
Mivan / Tunnel Form Formwork System:
General:
Mivan System/ Tunnel Formwork is a revolutionary aluminium formwork construction system, which has
been successfully used and developed, for forming cast in place reinforced concrete building structures.
Using this unique system, all walls, floor slabs, columns, beams, stairs, balconies, together with door and
window openings are cast in place in a single site based operation.
The resulting building structure is very strong, accurate in dimensions and tolerances, with a high quality
of finished concrete surface and yet at the same time the Mivan Formwork System is fast, adaptable and
very cost effective (subject to number of repetitions).
Characteristics of the Mivan System are that it makes use of concrete as the principal building material
for the prime reasons of cost and accessibility: Cement, sand and stone are readily available in most
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countries. Concrete also brings additional benefits in terms of it's build quality, strength, it's resistance
to earthquake tremors; it's resistance to fire, rot and vermin attack; it's low noise transmission with
good thermal capacity and it's proven durability, giving long life, with little maintenance. Contrary to
general belief Mivan System/Tunnel Formwork can construct all type of Concrete Structures.
Column, Beam & Slab Construction:
As compared to traditional method of construction, with Mivan System construction of these structures
may be finished in a fraction of the time. The construction of RCC framework is flowed by slow and
labour intensive follow-on wet trades, such as brick or block walls, which require heavy build-up of
plaster.
Wall & Slab Construction:
Mivan System Formwork makes full use of the structural efficiencies and operational advantages gained
from this method of concrete structure construction. A cellular building construction using all load
bearing walls adds strength, realising a saving on steel and concrete comparative to other structural
concrete systems such as column and beam or column and slab constructions. The need for slow and
labour intensive follow-on wet trades, such as internal brick or block work walls, is removed entirely and
the high quality of finished formed surface achieved by the aluminium panels eliminates the need for
costly plastering, as only a 4–5mm skim coating of plaster is all that is required for a perfect finish.
SPECIFICATIONS:
Components of Mivan system formwork / Tunnel form:
Material:
Panels are the basic element of Mivan formwork system. Panels are made from high strength aluminium
alloy with 4 mm thk skin plate and 6mm thk ribbing under panel which stiffens the panel. This panel,
even though lightweight has considerable stiffness and is capable of carrying large concrete weight,
when concrete is in plastic stage.
1) Beam component:
Beam side panel
Beam soffit panel
Prop head for soffit beam
Beam side bulkhead.
2) Slab component:
Deck panel
3) Wall component:
Wall panel
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Rocker
Kicker
4) Other component:
Internal soffit corner
External soffit corner
Stub pins
WALL COMPONENTS:
1) Wall Panel: - It forms the face of the wall. It is an Aluminium sheet properly cut to fit the exact size of
the wall
Fig: Wall Panel
2) Rocker: - It is a supporting component of wall. It is L-shaped panel having allotment holes for stub pin.
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Fig: ROCKER
3) Kicker: - It forms the wall face at the top of the panels and acts as a ledge to support.
Fig: KICKER
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4) Stub Pin: - It helps in joining two wall panels. It helps in joining two joints.
Fig: STUB PIN
BEAM COMPONENTS:
1) Beam Side Panel: - It forms the side of the beams. It is a rectangular structure and is cut according to
the size of the beam
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Fig: BEAM SIDE PANEL
2) Prop Head for Soffit Beam: - It forms the soffit beam. It is a V-shaped head for easy dislodging of the
formwork.
Fig: PROP HEAD FOR SOFFIT BEAM.
3) Beam Soffit Panel: - It supports the soffit beam. It is a plain rectangular structure of aluminum.
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Fig: BEAM SOFFIT-PANEL
4) Beam Soffit Bulkhead: - It is the bulkhead for beam. It carries most of the bulk load.
Fig: - BEAM SOFFIT BULKHEAD
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DECK COMPONENT:
1) Deck Panel: - It forms the horizontal surface for casting of slabs. It is built for proper safety of
workers.
Fig: DECK PANEL
2) Deck Prop: - It forms a V-shaped prop head. It supports the deck and bears the load coming on the
deck panel.
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Fig: DECK PROP
3) Prop Length: - It is the length of the prop. It depends upon the length of the slab.
Fig: DECK PROP LENGTH
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4) Deck Mid – Beam: - It supports the middle portion of the beam. It holds the concrete.
Fig: DECK MID-BEAM
5) Soffit Length: - It provides support to the edge of the deck panels at their perimeter of the room.
Fig: SOFFIT LENGTH
6) Deck Beam Bar: - It is the deck for the beam. This component supports the deck and beam.
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Fig: DECK BEAM BAR
OTHER COMPONENTS:
1) Internal Soffit Corner:
Fig: INTERNAL SOFFIT CORNER
2) External Soffit Corner:
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Fig: EXTERNAL SOFFIT CORNER
3) External Corner:
Fig: EXTENAL CORNER
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4) Internal Corner:
Fig: INTERNAL CORNER
Acceptance at the time of delivery:
1) Since the material is delivered in containers, care shall be taken during transportation, so that the
material is not damaged.
2) Once container is brought to site, unpacking shall be done strictly as per supplier’s instructions. All
components shall be checked for their proper labelling and easy identification.
3) Components of formwork shall be subjected to trial erection at site. If the delivered formwork does
not satisfy these criteria, the same shall be brought to the notice of supplier. Remedial measures shall
be taken in consultation with supplier. (It includes rejection of entire lot if mistake arises on the
supplier’s part.)
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4) Thickness of skin plate (4mm) and ribbing behind (6mm)as stiffener shall be checked unless any
deviation in thickness is agreed upon. Edges of all formwork members shall be smooth and corners free
from burrs.
5) Storage of formwork component at site shall be strictly as per supplier’s instructions.
NOTES:
Mivan formwork is a specialized formwork manufactured by few companies abroad. For Mivan, it is
necessary to freeze all dimensions of structure, wall openings, door & window frame / openings, room
height etc. and submit at least 3 months in advance to the supplier. Once the formwork design is
finalized, no further changes can be made.
PROCEDURE:
A) Pre-concreting:
1) All slab surfaces shall be cleaned of all debris, concrete waste, grease etc. On the cleaned slab surface,
wall layout is clearly marked using a suitable marker.
2) All formwork components shall be checked for any deformity and deformed components shall be kept
aside.
3) Formwork components are then applied with releasing agent as suggested by supplier. If there is no
such recommendation, the same shall be suggested by RCC Consultant. In any case, releasing agent shall
be from reputed manufacturer and it will not stain the concrete surface.
4) Formwork components shall be erected sequentially as per the numbering done on it and erection
drawing from supplier shall be referred. Pins and wedges are locked to secure different components of
formwork in place.
5) Levels of beam and deck soffits shall be checked with the help of auto level. All walls shall be erected
in true plumb. Slab surface for wall casting shall be perfectly levelled so that there is no gap between
rocker and slab level. Rocker is erected first before erecting wall panels.
6) All openings shall be checked for level; plumb and sizes and soffits levels shall also be checked. All
electrical conduits and electrical boxes shall be placed in correct position as per drawing and screwed to
components. All wall ties shall be covered with plastic sheet.
7) Beam and deck props shall be checked for plumb. Working platform shall be erected with brackets to
external walls.
8) Gaps (Gabadi) in ply shall not be used to cover up any area. Instead 4 – 6 mm thk aluminium sheet
fabricated to correct size shall be used.
B) During -concreting:
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MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 70 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
1) Adequate supervision shall be kept during concreting to ensure that pins, wedges, etc. are not
loosened due to vibration and deck / wall panels are not moved form their original position.
2) Gaps in the formwork shall be sealed if any by masking tape. High frequency vibrators shall be used at
all times during concreting. Use of kickers shall be made to act as supports for erecting next height of
wall panels. Rate of pouring concrete shall not exceed 2m in height / Hr.
C) Post-concreting:
1) Striking of formwork shall be done, after a pre decided period. Striking of formwork shall be done in
following sequence.
a) wall forms.
b) deck props
c) deck panels
d) beam soffits props
e) beam soffits
f) beam side panels.
2) Plastic sheet covering all ties shall be pulled out along with wall ties and holes shall then be grouted
using approved non-shrink material.
3) After striking, all forms (concrete side faces) shall be immediately cleaned with scraper whereas (non
concrete side faces) shall be cleaned off all dirt, concrete droppings, etc. using wire brush. Formwork
component shall then be stacked as per supplier’s instructions till further use.
NOTES:
For details in Mivan formwork system please refer to Mivan Formwork Procedure Manual
FORMWORKS ASSEMBLE:
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Fig: WALL ASSEMBLY DETAILS
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NAME:
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Fig: BEAM ASSEMBLY DETAILS
Fig: Erection of Platform
Striking of all forms can be done within 10-15 hours. The only tool required for dismantling is Hammer.
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Fig: Striking of formwork
Positioning of working platform bracket on 3rd floor level and securing nuts on tie rod on inside the
building.
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Fig: Positioning of Platform
nd rd
Removing Kicker from 2 floor level and Erecting all formwork on 3 floor.
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Page 76 of 864
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MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
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Fig: Positioning of Platform
PROCEDURES FOR CONCRETING
Step 1 – Mix Design Approval:
Latest mix design for concrete shall be available on site. Mix Design and trials of mix shall be carried out
as per the requirements of SANS to check workability, setting time, actual density, strength and cement
consumption (yield) whether it is site produced concrete or ready mix concrete. For site produced
concrete, all the concrete ingredients viz. Cement, Mineral admixtures like fly ash, GGBS etc., Silica
fume, Water, Aggregate, Chemical admixture etc. used should satisfy the requirements for the safety,
structural performance, durability and appearance of the finished structure, taking full account of the
environment to which it will be subjected. The selection and use of materials shall be in accordance with
SANS and all materials shall meet the requirements of relevant BIS specification. If Ready Mix concrete
has to be procured following specification shall be followed by the supplier of ready mix concrete
supplier:
SPECIFICATION FOR SUPPLY OF READY MIX CONCRETE
1) All the concrete ingredients viz. Cement, Mineral admixtures like fly ash, GGBS etc., Silica fume,
Water, Aggregate, Chemical admixture etc. used should satisfy the requirements for the safety,
structural performance, durability and appearance of the finished structure, taking full account of the
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environment to which it will be subjected. The selection and use of materials shall be in accordance with
SANS and all materials shall meet the requirements of relevant BIS specification.
2) All the mix designs shall be approved by Client & MES. And our structural consultants where ever
required. It is essential to carry out laboratory trials and complete data of trials shall be submitted for
approval. Laboratory trials shall generate base data on 1 day, 3 days, 7 days, 28 days, 45 days and 56
days compressive strengths for the selected set of ingredients. Attempt should be made to establish
correlation between these strengths. The correlation will change if the source of any ingredient is
changed, in which case a fresh correlation should be established and approval should be taken for the
new mixes. MES & client Representatives shall be allowed to witness such trials.
3) Minimum Cement Content, Maximum Water Cement Ratio and Maximum Cement Content shall be as
per the requirements of SANS with respect to the exposure conditions specified there in.
4) Client & MES requirement of workability at the pump point as measured by slump test shall be
between 140-160 mm, so that after pumping to the desired location the slump is minimum120 mm. Any
concrete shall be designed for a minimum three hours retention/open time. The workability of the
concrete shall be controlled on a continuous basis during production and any corrective action
necessary taken. No additional water, other than the amount required to produce the specified grade of
concrete as per mix design, shall be added to the truck mixer drum before discharge unless specifically
requested and signed for by MES & Client representative. Re-dosing or split dosing shall be allowed
subject to the written permission of trained technicians and Engineers from MES & client... In any case,
the total dose should not exceed the maximum dose of admixture declared by Supplier or
recommended by Admixture supplier. The supplier shall stock at least 50 litre of admixture with MES &
Client Quality Control department at site.
5) Any concrete poured should get finally set within maximum 24 hours.
6) Any concrete of a specified Grade shall meet the characteristic strength in 28 days. Any concrete
being supplied to our site, which does not achieve minimum characteristic strength at 28 days, shall be
considered as failure and no other acceptance criteria shall be entertained.
7) It is important to maintain the water cement ratio constant at its correct value. The amount of added
water shall be adjusted to compensate for any observed variations in the moisture contents in the
aggregates. Suitable adjustments should also be made in masses of the aggregates due to this variation.
Any change in water content due to change in aggregate grading shall be taken care of by forward
control by suitable modifications to mix design.
8) Batch sheets, moisture correction calculation/sheet shall be submitted along with challahs for every
pour of concrete. The scope of addition of extra admixture (over and above the quantity which has
already been added at the time of batching at plant) shall be declared by concrete supplier. Immediately
before discharging the concrete at the point of delivery, the producer or his representative shall provide
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Page 78 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
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MES & client representative with a pre-printed delivery ticket for each delivery of concrete on which is
printed, stamped or written the minimum information detailed below. The delivery ticket will form the
basis of invoicing. The following information shall be included in the delivery ticket to accompany the
load to MES & client:
Name or number of the ready-mixed concrete depot.
Serial number of the ticket.
Date.
Truck number.
Name of the Purchaser, Name and location of site.
Grade or mix description of the concrete.
Specified target workability.
Minimum cement content (if specified).
Type of cement and grade (if specified).
Maximum free water-cement ratio (if specified).
Nominal maximum size of aggregate.
Generic type or name of any chemical and mineral admixtures included.
Workability/Slump at plant
Admixture dosage added at plant
Quantity of concrete in cubic meter.
Time of loading.
Signature of the plant operator.
On site the following information will be added:
Time of arrival on site.
Time when discharge was completed.
Any water / admixture added by the supplier to meet the specified workability.
Any extra water or admixture added at the request of Client & MES representative and his
signature.
Pouring location.
Signature of the purchaser or his representative confirming discharge of the load.
9) Ready-mixed concrete shall be transported from the mixer/batching plant to the point of placing as
rapidly as practicable by methods that will maintain the required workability and will prevent
segregation, loss of any constituents or ingress of foreign matter or water. Concrete shall be transported
in a truck-mixer or agitators unless Client & MES agrees to the use of non-agitating vehicles.
10) For the assessment of compliance of ready-mixed concrete, the sampling may be carried out jointly
by Client & MES and the supplier with its frequency mutually agreed upon. However, it will not absolve
the supplier of his responsibility from supplying concrete as per the requirements given in standards
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(SANS) or otherwise mutually agreed terms and conditions. Any special clause mentioned in this
specification shall be binding on supplier of concrete. The point and time of sampling shall be at
discharge from the producer’s delivery vehicle or point of final placement.
11) Concrete mixes shall be randomly sampled and tested for workability, and where appropriate,
plastic density, temperature and air content. Where significant variations from target values are
detected, corrective action shall be taken.
12) Concrete supplier shall submit the following information, reports and test certificates before
approval of mix design and in the event of change of source of raw material:
Source and brand of different ingredients of concrete,
Gradation, specific gravity, water absorption, mechanical properties, deleterious material report
of fine and coarse aggregate,
Report on alkali silica reactivity and soundness of aggregates,
MTC of cement/external test report,
Chemical and physical test report of Fly ash as per requirements of SANS,
Physical and chemical test report of chemical admixture,
Water test report for each source,
Mix Design Stipulations and final mix data,
Results of concrete mix design trials: Workability at 0, 1, 2, 3 Hrs., Cohesiveness, density, Yield of
concrete, Initial and final setting time of concrete, strength results at 1,3,7,28,45 and 56 days.
13) Concrete supplier shall submit the following information, reports and test certificates on a monthly
basis:
Change of Source and brand of different ingredients of concrete,
Correction of Mix design if required,
Gradation, specific gravity and water absorption for each source of fine and coarse aggregate,
MTC of cement or external test report,
Physical test report of Fly ash – Fineness and LOI,
MTC of each lot of admixture and uniformity test report,
Water test report if source changes,
Compressive strength results at 3, 7 and 28 days for all the pours of concrete,
batching plant calibration report.
14) Records shall be maintained by the producer to provide confirmation of the quality and quantity of
concrete produced. The records shall be retained for the purposes of these requirements for a period of
at least one year. They shall cover the following aspects:
Production and delivery:
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Batching instructions,
Batching records,
Delivery tickets, and
Equipment calibration and plant maintenance.
Materials and production control:
Concrete production and materials purchase, usage and stocks, and
Certificates or test results for materials.
Production quality control:
Control test results
15) All other requirements pertaining to Materials, Storage of Ingredients, production, delivery, batching
equipment, quality control, sampling, order processing etc. as specified in SANS – “READY MIXED
CONCRETE-CODE OF PRACTICE” shall be binding on the producer / supplier of concrete.
16) Any additional compliance criteria (project specific) shall be declared to the producer by MES &
SVHL’S . prior to supply and shall be mutually agreed upon in terms of definition, tolerance, frequency of
assessment, method of test and significance of result. If there is any specific requirement other than
above requirements like temperature control, early strength etc. for a particular project, such
requirements shall be intimated to the supplier by MES & SVHL in advance.
17) The action to be taken in case of non-compliance shall be declared and mutually agreed upon.
18) In case of failure of strength (as estimated by cube strength), Cores shall be drilled out from the
structure with strength failure and shall be tested for compressive strength and equivalent cube
strength must meet the requirements of relevant BIS standard. No other NDT shall be entertained. The
cost of Core drilling and testing shall be born by the supplier of concrete. Further the results shall be
forwarded to MES & Structural consultant for his opinion and his decision shall be binding on both the
parties – Client & MES and the Supplier of concrete.
19) If the equivalent cube strength of the drilled cores does not meet the requirements of BIS codes,
then the matter shall be referred to MES / Client structural consultant and as per the recommendation
of the Structural Consultant, the structure shall be demolished and reworked or strengthened. The cost
for such demolition/ breaking, reworking including cost of labour and material such as steel
reinforcement, concrete, electricity etc. or the cost of strengthening the structure shall be born by the
supplier.
Step 2 – Site Preparation
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Dewatering of area to be concreted shall be carried out if required. Also area shall be cleaned of any
dirt, debris, waste material, binding wires etc.
Step 3 – Pre Concreting Checks
1) Necessary latest drawings shall be made available on site.
2) Checking of form work, supports and scaffolding shall be done as per the available latest drawings.
3) Checking of various activities such as reinforcement, cover blocks, embedded electrical conduits,
plumbing lines, inserts etc. shall be done as per drawing.
4) Sequence of concreting and location of stopper shall be decided and clearly marked on drawings
available on site.
5) Moisture correction for sand shall be calculated and net quantity of water to be added per bag of
cement shall be decided to maintain water cement ratio as per mix design.
6) Wetting of coarse aggregates shall be carried out 24 hours before actual concreting in case of site
produced concrete.
7) Availability of necessary raw materials and equipment shall be ensured.
8) Appropriate de-shuttering agent should be applied on formwork.
9) Checklist / QA card should be appropriately filled taking into account all the points are maintained
properly at site.
10) In case of site produced concrete, concreting shall be preferably done on weight basis. However if
volume batching has to be resorted to, conversion into volume shall be done by calculating DLBD of
coarse / fine aggregates and also taking into account Bulk age Factor for sand.
11) Pharmas of correct sizes shall be prepared and maintained in proper condition in such cases.
12) Sufficient concrete handling, compaction (vibrators) and curing arrangements with respect to size of
the pour, depth of pour, spacing of reinforcement etc. must be ensured before starting concrete if site
produced concrete or before ordering concrete from approved supplier.
Step 4- During Concreting Checks
General:
1) Before starting concrete for the day, the gradation of fine and coarse aggregate shall be checked and
if any deviation in combined gradation is observed, necessary corrections in percentage of aggregates
shall be made to achieve the desired combined gradation. This will ensure that concrete is cohesive and
free from segregation and bleeding.
2) The concrete pipeline of pump shall be checked to ensure whether there is any leakage of slurry,
which may affect the pumpability of concrete.
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3) During concreting it must be checked whether there is any slurry leakage from the shuttering and
corrective measures should be taken immediately because this may affect finishing because of
honeycombing and final performance of the concrete and aesthetics.
4) Variation in pipe diameter of pump and number of bends in the pipeline should be restricted to
minimum.
5) The supports/props must be checked during concreting to avoid bulging and potential failure of
shuttering because of the weight of wet concrete.
6) Pouring height must be restricted as per the site condition with suitable methods to avoid segregation
of concrete.
7) Availability of sufficient equipment and manpower for compaction of concrete must be ensured
8) Vibrator needle size shall be appropriate as per the spacing of the reinforcement and workability of
the concrete. Influence radius should be checked by visual observation.
9) Over vibration of concrete should be avoided, which may lead to deposition of slurry at the top
leading to crazing cracks any time during hardening. Over vibration may also lead to bleeding resulting in
plastic settlement and subsequent cracks.
Site Mixed Concrete:
1) Weights of aggregates shall be adjusted in the first 5 batches to get required slump, without changing
the water cement ratio given in the mix design.
2) Corrections shall be done in the mix proportions (aggregates, sand volume correction) to get cohesive
homogeneous mix of desired workability.
3) Batching shall be done by sandwiching the cement between fine and coarse aggregate. Preferable
sequence is coarse aggregate, cement and then sand.
4) Minimum mixing time of 1½ minutes shall be adhered to, for every batch of concrete. Hence
maximum output of mixer shall not exceed @30 bags per hour, if one bag mixer is used.
5) Unloading of concrete mix shall be done on MS tray / concrete platform.
6) Slump reading shall be recorded after every 25 bags and slump variation shall not exceed 25mm from
the designed workability.
7) Presence of qualified supervisor at the weigh batcher / concrete mixer, at place of concreting and at
shuttering shall be required.
8) First batch of concrete shall be prepared by addition of 10% extra cement to allow for loss in the
drum.
9) Exact quantity of water as per moisture correction applicable shall be added using water dispenser /
calibrated cans. Buckets shall not be used.
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10) Concreting works shall be arranged so as to have minimum cold joints.
11) While pouring concrete, segregation of concrete shall not be observed.
12) Cubes shall be taken during every concreting. Number of samples and testing shall be in accordance
with SANS. Each cube shall have proper identification mark as regards grade, date of casting, location
etc. Cube sampling shall spread over entire period of concreting.
13) While cubes are being taken for testing, corresponding slump shall also be recorded, in cube testing
register. Cubes shall be cast in the presence of Engineer.
14) During every day’s concrete unit weight of concrete as specified in SANS shall be checked and
compared with theoretical density of concrete (sum of weight of all ingredients). If any significant
deviation is observed, it indicates corrective measures are required in Concrete Mix Design.
15) In case of pre stressed concrete more no. of cubes shall be casted for estimation of desired strength
on the day of stressing.
16) At high altitudes wind breakers shall be provided while concreting.
Ready Mix Concrete:
1) Transit trucks shall comply with the relevant code, with an agitating speed between 2 and 3 RPM and
mixing speeds in the range of 10-20 RPM.
2) Before unloading of any truck at the site, the RMC supplier shall supply a certificate/batch sheet (a
computerized sheet) along with moisture correction for the concrete, mentioning proportions of all the
ingredients, w/c ratio, dosage of plasticizer and relevant admixtures etc. (please refer Specification for
Supply of RMC).
3) The maximum water cement ratio, as specified in the approved mix design shall not be exceeded.
4) The information provided by RMC supplier shall be cross checked at site, and in all cases slump shall
be taken prior to concreting. The accuracy of the measuring equipment shall be within + 2 percent of the
quantity of cement and mineral admixtures being measured and within + 3 percent of the quantity of
aggregate, chemical admixture and water being measured.
5) Concrete which needs to be pumped shall have workability between 120 to 150 mm or as specified
when the transit mixer arrives. Any concrete shall be designed for a minimum three hours
retention/open time. The workability of the concrete shall be controlled on a continuous basis during
production and any corrective action necessary shall be taken. No additional water, other than the
amount required to produce the specified grade of concrete as per mix design, shall be added to the
truck mixer drum before discharge unless specifically requested and signed for by MES & Client
Representative. Redoing or split dosing shall be allowed subject to the written permission of trained
technicians and Engineers from Client & MES.. In any case, the total dose should not exceed the
maximum dose of admixture declared by Supplier or recommended by Admixture supplier.
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 84 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
6) It shall be ensured that the retardation time achieved by the use of admixtures does not exceed the
time required for transit and actual placement of concrete. This shall be achieved by checking the time
of dispatch of transit mixer mentioned on challan. Any Concrete is being designed with the help of water
reducing agents and retarders for a stipulated retention time. So the concrete must be consumed within
the same time as considered in design. Our all concrete mixes must be designed for 3 hours retention
time, so concrete must be consumed within 3 Hours from the time of batching. If the workability of
concrete is higher than desired workability and segregation & bleeding is observed, we should allow
some time to elapse before discharge till workability drops to the range of 120 to 150 mm. If workability
is less, then re-dosing or split dosing shall be allowed but in any case, the total dose should not exceed
the maximum dose of admixture declared by Supplier of concrete or recommended by Admixture
supplier. We must avoid over dosing which may cause delay in setting of concrete
7) Temperature of concrete at the time of pumping shall be less than 40ºC or as mutually agreed
between MES & Client. and Supplier of Concrete.
8) The cohesiveness and mixing of the concrete should be checked, there should be no lumps, bleeding
or segregation in the concrete.
9) During every day’s concrete unit weight of concrete as specified in SANS shall be checked and
compared with theoretical density of concrete (sum of weight of all ingredients). If any significant
deviation is observed, it indicates corrective measures are required in Concrete Mix Design. Supplier of
concrete shall be immediately informed as this variation may impact yield of concrete or desired
properties of the concrete
10) Concrete carrying pipes shall not be allowed to rest on top reinforcement which is likely to bend.
Leakage of slurry from concrete pipeline should be checked and rectified.
12) At high altitudes wind breakers shall be provided while concreting
Footings
1) PCC should be done in level as per given size in drawing with Dobra marking.
2) Demarcation of foundation should be done with correct orientation of column as per centre line plan.
3) All footings shall rest on PCC of M15/M10 Grade concrete, having minimum thickness of 150mm /
75mm or as per drawing.
4) Concrete shall be cast in max 450mm layers and vibrated by 60mm vibrating needle.
Columns and Shear walls
1) Platform erected for labour for concreting shall be independent of column shuttering.
2) If required, Grade of concrete for column starters shall be one grade higher than that of column
concrete.
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Property of MSS – Approved (Controlled document in Document Repository)
FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 85 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
3) Minimum height of starters shall be 6” to 9” and shuttering shall be of fabricated steel / steel
channels or plywood. (Planks or fali should not be used in sides of starters.) Concrete within shall be
suitably vibrated and cured.
4) Formwork for starters of column / shear walls when erected shall be checked using theodolite / line
dori for the correctness of dimensions and orientation (including offsets if any).
5) Thick Mortar slurry of 1:1 cement sand mix shall be poured at base of columns to prevent
honeycombing. This mortar slurry shall have water cement ratio 0.05 less than that recommended for
concrete mix.
6) Concrete for columns shall be cast and vibrated in layers of 450mm.
7) Column concreting shall be done up to lowest level of beam bottom at the junction.
8) Concrete key shall be made at top surface of column for better bond with next pour/ 20mm metal
packing shall be done on top of concrete surface for proper bonding with next pour / chipping of top
surface for removal of laitance.
9) If reinforcing bars are congested at the junction of column and beam, a special concrete mix of higher
grade using 10mm aggregates may be used therein.
Slab and Beams
1) Concrete from hoist shall be unloaded on MS tray
2) Walking platforms shall be provided for easy movement of labour without disturbing the
reinforcement.
3) Level marking / ghodi having height equal to thickness of slab shall be used while slab concreting is in
progress.
4) Concreting area for the day shall be well demarcated and concreting shall commence from the
farthest end and proceed towards direction of hoist. In case of pumping, proper planning should be
done for placing of concrete.
5) Slab top levels shall be checked during and after finishing with levelling instrument for controlling the
thickness of slab.
6) Beams and slabs having depth more than 150 mm shall be vibrated by 25/40/60 mm needle
depending on size of beams and spacing of reinforcement, whereas slabs having thickness of less than
150 mm shall preferably be vibrated by surface vibrator. The spacing of inserting the vibrating needle in
concrete shall be as follows:
25mm needle – 150mm c/c
40mm needle – 300mm c/c
60mm needle – 450mm c/c
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Property of MSS – Approved (Controlled document in Document Repository)
FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 86 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
7) Care shall be taken not to over/under vibrate the concrete. While withdrawing vibrator needle no
holes
shall be visible in concrete.
8) Concrete shall be placed in layers not exceeding 450mm deep in deep beams and placed to the full
depth in
slabs and small beams. Each layer shall be placed and well compacted before the preceding layer has
taken its
initial set and in a manner that will entirely prevent any cold joint forming between the layers.
9) If concrete is being placed by pump or crane bucket, concrete should not be poured directly in to the
beams.
10) If grade of concrete for slab and columns is different, column portion shall be cast first before slab
concreting starts. Care shall be taken to prevent formation of cold joint at junction i.e. portion adjoining
columns shall be cast before initial setting starts in columns. Welded wire mesh or equivalent shall be
used as stoppers to prevent excess concrete from columns to flow into beams.
11) Construction joint in beams shall be provided as per drawings or in absence of such drawings, where
shear force is zero. Cement sand slurry of 1:1 with bonding agent shall be used at construction joints to
create better bonding between old and new concrete. At construction joints, new concrete shall be
over-vibrated for proper bonding with old. Wooden stoppers with step shall be provided at construction
joints in such a way so as to facilitate their easy removal.
12) Slab panels shall be covered with wet Hessian cloth, tarpaulin or plastic sheets immediate after
concreting, after initial set occurs, to prevent formation of shrinkage cracks.
Step 5- Post Concreting Checks
Curing
1) Curing is the process of preventing the loss of moisture from the concrete whilst maintaining a
satisfactory temperature regime. For all concrete works, curing shall be start immediately after
deshuttering and for slab and raft surface immediately after initial setting of concrete by sprinkling or
covering with wet hessian cloth.
2) Exposed surfaces of concrete shall be kept continuously in a damp or wet condition by ponding or by
covering with a layer of sacking, canvas, hessian or similar materials and kept constantly wet for at least
7 days from the date of placing concrete in case of ordinary Portland Cement and at least 10 days where
mineral admixtures or blended cements are used.
3) The period of curing shall not be less than 10 days for concrete exposed to dry and hot weather
conditions & 14 days where blended cement is used.
Protection of concrete
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Property of MSS – Approved (Controlled document in Document Repository)
FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 87 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
1) Newly placed concrete shall be protected from rain, sun and wind by approved means viz: Hessian
cloth, plastic sheets etc.
2) Concrete placed below the ground level shall be protected against contamination from falling earth,
during placing.
3) The area in and around the actual place of the concreting shall be kept sufficiently dry, by
constructing sufficiently watertight forms / cofferdam around the area to be concreted, to prevent loss
of mortar through walls.
4) Continuously dewatering the area throughout the period of concreting and till initial set of concrete
occurs with the help of dewatering pumps shall not be resorted to.
Columns / Shear walls
1) Curing shall be done keeping the concrete surface wet by covering it with moist double Hessian cloth
2) Curing shall continue for at least 10 days.
Slabs
1) Curing of slabs shall be done as mentioned above.
2) Ponds shall be made within 24 hours of slab casting and till then slab shall be cured by spraying water.
3) Ponds shall be made at column locations first to cover from all sides and then to cover other portions
of slab.
4) Care shall be taken to see to it that ponds are completely filled with water throughout the
recommended period for curing.
5) Vertical faces of the beams and area of slab outside ponds shall be cured by covering with wet
Hessian cloth.
6) In case where ponding is not done, whole slab should be covered with wet hessian cloth and care
should be taken to keep it moist always.
Footings
1) Flat portion of footings shall be cured by covering it with wet double Hessian cloth.
2) For flat portions of Rafts, curing shall be done in a similar way as that for slab and vertical faces shall
be cured similar to the columns.
General:
1) All the flat portions of footings / underground structures shall be applied an epoxy based bituminous
layer for protection against ground water.
2) RCC surface (footing faces, plinth beam sides, below PCC, periphery of the building) below ground
level should be given approved anti-termite treatment.
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 88 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
3) Backfilling shall be started after footings are cured. Backfilling shall be carried out in layers of 300mm
to 450mm thick good quality Laterite, which shall be well watered (up to Optimum Moisture Content)
and compacted by using mechanical vibrator.
4) Date of casting should be displayed on concrete surface with identification after de-shuttering to
monitor curing.
5) If honeycombs observed are of repairable nature (which do not require demolition of member, in the
opinion of Structural Consultant), the same shall be rectified by using approved non shrink mortar mixed
with bonding chemical.
6) If it is intended to have plaster or masonry against the concrete structure, the surface shall be hacked
(approx. 60/70 hacks each 2-3mm in depth, 1” length and 1” apart per sq.ft) within 48 hrs. After de-
shuttering or it is preferable to use approved bonding agents instead of hacking.
7) Reinforcement bars projecting above cast concrete shall be cleaned, using wire brush.
8) Tie roads and PVC pipes must be removed immediately after de-shuttering.
9) Columns below natural ground should have 20mm additional covering or as recommended by
structural consultant and Winged Cover Kanda should be used to maintain alignment of reinforcement
and covering.
Step -6 Concrete Cube Sampling
Site Mixed Concrete:
The minimum frequency of cube casting shall be as follows if concrete is produced at site mixer. Each
sample shall consist of 3, 6 or 9 cubes depending on whether cubes shall be tested at only 28 days or 7 &
28 days or 3,7 and 28days.
Concrete Quantity Number of samples
3
Up to 5 m 1
3 3
6m to 15m 2
3 3
16m to 30m 3
3 3
31m to 50m 4
4 + one additional for each additional 50 m 3 or
More than 50m3
part thereof
Ready Mix Concrete:
For the assessment of compliance of ready-mixed concrete, the sampling may be carried out jointly by
Client & MES. And the supplier with minimum frequency as specified in IS 4926:2003 or otherwise
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Property of MSS – Approved (Controlled document in Document Repository)
FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 89 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
mutually agreed upon. However, it will not absolve the supplier of his responsibility from supplying
concrete as per the requirements given in standards (SANS) or otherwise mutually agreed terms and
Conditions. The point and time of sampling shall be at discharge from the producer’s delivery vehicle or
point of final placement.
Concrete Quantity No. of Samples to be taken
Up to 50 cu.m. or 50 batches whichever is of One Sample
higher frequency
More than 50 cu.m. One additional sample for every 50 cum. or 50
batches whichever is of higher frequency
The sampling methodology from Transit Mixer shall be as follows:
Let very first concrete go – at least the first one third of a cubic meter of concrete.
• Take a scoopful from part 1
• Take a scoopful from part 2
• Take a scoopful from part 3
• Take a scoopful from part 4
Let the last concrete go. Thoroughly remix this composite sample either on a mixing tray or sampling
bucket. Then we should proceed with required testing.
Step-7 Casting and testing of Cubes:
For the assessment of compliance of ready-mixed concrete or site mixed concrete, the point and time of
sampling shall be at discharge from the producer’s delivery vehicle to pump or site or discharge from
mixer respectively.
The following steps should be observed:
(a) Check if moulds are cleaned & lightly oiled.
(b) In assembling the mould for use, the joints between the sections of mould shall be thinly coated with
mould oil and a similar coating of mould oil shall be applied between the contact surfaces of the bottom
of the mould and the base plate in order to ensure that no water escapes during the filling.
(c) Ensure angle between adjacent internal faces & between internal faces shall be 90°C + 0.5°C.
(d) Thoroughly remix the sample shovelling into a heap
(e) Fill the mould with concrete in 50 mm layers
(f) 35 tamps for each of the three layers in 150 mm mould or vibrating table
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Property of MSS – Approved (Controlled document in Document Repository)
FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 90 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
(g) After filling each layer tamp sides with a wooden mallet to expel out any entrapped air
(h) The workability of concrete at time of filling cubes should be between 75 -100 mm.
(i) Remove surplus concrete & number the moulds for identification & record details.
(k) Cover each mould with damp cloth / Hessian cloth immediately after initial set.
(l) Store at a place free from vibration. Protect the cube moulds at all times from high / low
temperatures & driving winds.
(m) Complete Sampling & cube making certificates or records.
(n) After de-moulding the cubes shall be immediately submerged in clean, fresh water or saturated lime
solution and kept there until taken out just prior to test (Temperature 24°C to 30°C).
(o) The specimens shall not be allowed to become dry at any time until they have been tested.
(p) The testing machine may be of any reliable type, of sufficient capacity for the tests and capable of
applying the load at the rate of 14 N/mm 2/minute. The permissible error shall be not greater than ± 2 %
of the maximum load.
(q) The bearing surfaces of the testing machine shall be wiped clean and any loose sand or other
material removed from the surfaces of the specimen which are to be in contact with the compression
platens.
(r) The specimen shall be placed in the machine in such a manner that the load shall be applied to
opposite sides of the cubes as cast, that is, not to the top and bottom.
(s) Average of three values shall be taken as the representative of the batch provided the individual
variation is not more than ± 15 % of the average.
(u) If failure is observed during the testing of the first cube, stop testing the balance two cubes,
immediately inform the senior authority of Client & MES. And the supplier of the concrete and test the
balance two cubes in presence of the supplier’s authorized representative and have a joint record.
(v) The following information shall be included in the report on each test specimen:
a) Identification mark,
b) Date of test,
c) Age of specimen,
d) Date of casting,
e) Weight of specimen,
f) dimensions of specimen,
g) Cross-sectional area,
h) Maximum load,
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 91 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
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j) Compressive strength, and
k) Appearance of fractured faces of concrete and type of fracture, if these are unusual.
Step -8 Hot / Cold Weather Concreting Requirements
1) In hot weather, (temperature of surrounding higher than 40ºC) concrete shall be transported in deep
containers to reduce the loss of water due to evaporation and the same method for transport shall be
adopted in cold weather ( temperature of the surrounding lower than 15ºC) to reduce heat loss.
2) In hot weather, work shall be restricted to the cooler parts of the day. The formwork shall be
continuously sprayed with cold water in advance of actual concreting. Excess water shall be removed
from inside of forms, just prior to the concrete placement.
3) The reinforcement and formwork, if metal forms are used, shall be protected from the effects of hot
winds and direct sunlight.
4) The concrete shall have a temperature not higher than 40ºC when placed. This shall be achieved by
making use of chilled mixing water, flaked ice or by spraying water on the coarse aggregate (pre-cooled
aggregates) or both, and if necessary by covering the container in which the concrete is transported to
the site by wet Hessian cloth.
Step -9 Acceptance of completed work
Inspection of concrete after removal of formwork and Corrective Measures:
1) On removal of formwork, the surface shall be examined by Engineer. The inspection shall be carried
out to check the finish of the concrete, deflections, bulges and other defects.
2) The corrective measures for the dimensional defects shall be taken in consultation with the structural
consultant.
3) If any structural cracks are observed, they shall be brought to the notice of the structural consultant
and shall be repaired at the earliest.
Acceptance of work as regards Structural stability:
1) In all cases 28 days cube strength shall be the basis for acceptance of concrete.
2) In case results of compressive strength of cubes show failure or low results than the acceptance
criteria, the same shall be immediately reported to the structural consultant for initiating further course
of action.
3) Structurally damaged members shall be brought to notice of Structural Consultant.
4) Certificate of Structural Consultant as regards safety of structure shall be obtained after each slab
construction.
5) Breaking of structural member shall generally be avoided unless specifically asked by the Structural
Consultant.
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 92 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
Step -10 Repair Work
1) Honeycombing, especially severe honeycombing shall not be patched up without showing the
conditions to the QA Engineer who would decide the remedy.
2) Honeycombs of mild and moderate nature, in the concrete, where the reinforcement inside is not
exposed, shall be repaired with use of approved Non-shrink mortar mixed with bonding chemical. The
repaired patch of concrete shall be cured for 7 days or by using curing compound as recommended by
manufacturer.
3) For repair of honeycombs in concrete, where reinforcement is exposed, epoxy grout shall be used for
the repair work and cured for 7 days or by using curing compound as recommended by manufacturer.
4) Brands of repair material and chemicals shall be approved by QA/QC Department for use to repair
surfaces of damaged concrete.
5) Through shrinkage cracks shall be grouted with approved non-shrink grout, whereas minor shrinkage
cracks shall be filled with cement slurry.
6) If a structural member requires to be demolished in the opinion of Structural Consultant, the same
shall be enclosed by forms from all sides before demolishing and supported adequately.
7) All repair works shall be carried out in accordance with the manufacturer’s recommendations as
regards the preparation of surface, cleaning, hacking, applying bonding agents, admixtures, polymer
mortars etc.
Step 11: Guidelines for Acceptance of Finished Product (RCC)
Type of Defect Tolerance / Acceptance
Visual
Visible offsets in column starters Not greater than 5 mm
Column offsets with beam Not greater than 5 mm
Column cap (column topi) plumb Should not be out of plumb by 5 mm
Visible bulge in Column cap (column topi) Not greater than 5 mm
Rebars exposed in columns No tolerance
Aggregates exposed in column Maximum 3% of Column Surface after
deshuttering but needs repairing.
Instruction given for Breaking column To be followed
Difference in plumb of column in successive floors Not greater than 5 mm
Visible offsets in beam sides Not greater than 5 mm
Rebars exposed in beams No tolerance
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 93 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
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CONTRACTOR
NAME:
Aggregates exposed in beams Maximum 3% of Beam Surface after
deshuttering but needs repairing.
Difference in beam bottom alignment Not greater than 5 mm
Type of Defect Tolerance / Acceptance
Visual offsets in slabs Not greater than 5mm
Aggregates exposed in slabs Maximum 3% of Slab panel Surface after
deshuttering but needs repairing.
Rebars exposed in slabs No tolerance
Measured
Bulge and right angle of columns, beams and lift 10 mm
pardi
Plumb of columns, beams and lift pardi 5 mm
Grid distance (face to face) for columns 5 mm
Outer plumb of beams / columns 5 mm
Bottom level difference in slab soffit 10 mm(+/-) in 3 m length
Top level difference in slab finished level 10 mm(+/-) in 3 m length
NOTES : After removal of shuttering
1) Honeycombs should not be observed
2) No wooden pieces / debris should be observed embedded in RCC
3) Offsets should not be present
4) Deep pockets should not be observed beyond rebar in columns / beams.
For practical purpose Honeycombs should be recorded as:
1) Minor honeycomb – After removal of shuttering, minor aggregates exposed with slurry leakage.
2) Moderate honeycomb – After removal of shuttering, moderate aggregates exposed with slurry
leakage.
3) Severe honeycomb - After removal of shuttering, aggregates as well as steel bars are exposed.
Guidelines for spacing “IN-PLACE” Cover Blocks
Bar Diameter Spacing centre to Approx. Nos. per Position of Cover
Nature of work
(mm) centre (mm) 100 sqft. Block
Slab / Raft Slab 8 600 25 Staggered in rows
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 94 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
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10 600 25
12 600 25
16 750 16
20 750 16
Columns 16 At three locations
20 Bottom
25 Centre
28 And 2” below
top level
32
Pardi / RCC Wall 8 600 25 Both sides of the
10 600 25 shuttering tied to
the outer
12 750 16
reinforcement of
16 750 16 the pardi and
20 850 12 staggered in rows
Beams 8 600 NA For bottom as
10 600 well as side
reinforcement,
12 600
spaced over total
16 600 area of shuttering
20 750 and staggered in
25 750 rows.
28 900
32 900
NOTES: 1. Strength of cover blocks shall be equal to the grade of concrete.
2. For proper compaction, cover blocks shall be properly vibrated to reduce permeability of cover block.
3. Plastic / PVC cover blocks can be used in place of concrete cover blocks by proper approval from QA
Department.
Guidelines for Spacing Of: “IN-PLACE” chairs for slab / Raft reinforcement
Diameter of the bar to be
Min. diameter chair Bar Position and Number of chairs
supported
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
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METHOD STATEMENTS
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PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
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10 mm 6 mm Minimum 1 no. for every bent up
12 mm 6 mm bar of the slab reinforcement
16 mm 8 mm Distance from overhang portion of
bent up bar should be 100 mm
20 mm 8 mm and distance between chairs
25 mm 12 mm should not exceed 900 mm
28 mm 12 mm
NOTES:
Above mentioned spacing and diameter of chair bars may be changed as per requirement at site
Size of the chair may be increased to support more than one bar with greater chair bar diameter.
Records :
Reference Documents :
ITP Reference No :
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METHOD STATEMENT
FOR
MASONRY WORK
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
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SR. EFFECTIVE REV. MSS MANAGER MSS PROJECT CLIENT
CLIENT QA/QC
NO. DATE NO. QA/QC MANAGER SUPERVISOR
MASONRY WORK
General:
There are various types of materials used for masonry works such as bricks, blocks (solid / hollow),
cellular light weight concrete blocks, fly ash lime bricks etc. The mortar used for above masonry
consisting of cement, sand natural as well as crushed, fly ash, water and admixtures. The details for the
above materials are as follows:
Cement:
For masonry works, following checks are important.
1) Cement shall be OPC 43 Grade and not more than 8 weeks old.
2) Cement shall be free from lumps.
Natural Sand:
Sieving of sand should be done for mortar for masonry. Gradation of sand for use in masonry mortars as
per SANS is given below for reference.
SIEVES Percentage passing by mass
4.75 mm 100
2.36 mm 90 to 100
1.18 mm 70 to 100
600 microns 40 to 100
300microns 5 to 70
150 microns 0 to 15
If grading of sand falls outside the specified limits as above, the required grading may be obtained by
screening and / or blending together natural sand and crushed sand having required size particles in
appropriate quantities.
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Silt content should not exceed 8 % by volume ( 3 % by weight ).
Fineness Modulus can vary from 1.5 to 2.5.
Washed / Crushed Sand:
For masonry works, following checks are important.
1) Fineness Modulus can vary from 1.5 to 2.5.
2) If grading of crushed sand falls outside the specified limits as above, the required grading may be
obtained by screening and / or blending together natural sand and crushed sand having required size
particles in appropriate quantities.
Water:
Water must meet the requirements of SANS and should be tested at a third party laboratory to check
the compliance before use.
Specifications:
Bricks:
In spite of various materials available for masonry works such as concrete blocks, stones, fly ash bricks
etc. traditional burnt clay bricks have their own importance in masonry works due to following
advantages.
Durability
Good for plaster / finishing works
Light in weight compared with concrete blocks
Good thermal insulation property.
Bricks shall be hand moulded or machine moulded, made from suitable soil and shall be free from
cracks, flaws and free lime. Bricks shall be well burnt, cherry red in colour, gives a ringing sound when
struck against each other. Bricks may have well defined frog of 10 mm to 20 mm depth and covering
about 15% of surface area as per relevant BIS. Bricks shall have smooth rectangular faces with sharp
corners and show uniformity in colour. Bricks used as partition walls shall confirm to minimum Class 3.5
as mentioned in SANS.
Bricks failing in dimensional analysis, especially in width parameter shall not be used for construction of
external walls to limit plaster thickness, avoid cracking and de-bonding of excessively thick plasters.
The inspection norms, acceptance criteria and frequency of test of bricks had been laid down in the
following table.
Sr.
Description Mode of Inspection Acceptance Criteria Frequency
No.
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1 Dimensional Field Test: Every Truckload /
Analysis 20 bricks at random are chosen Consignment
and placed on a plane horizontal
surface
For 20 bricks lot:
Theoretical length Vs Actual < +/- 80 mm
length < +/- 40 mm
Theoretical width Vs Actual < +/- 40 mm
width
Theoretical height Vs Actual
height
For individual brick ( out of 20
brick lot)
Max. length of Brick sample VS
Min length of Brick sample < 10 mm
Max. width of Brick sample VS
Min width of Brick sample < 5 mm
Max. height of Brick sample VS
Min height of Brick sample
< 5 mm
* All sides should be in right
angle and edges not broken.
2 Average Water External / Internal lab test Not more than 20% Once per source
absorption
3 Average wet External / Internal lab test Not less than 3.5 Once per source
Crushing MPa
strength
4 Efflorescence External lab test Not more than Every 10000
Coverage ‘Moderate’ as per IS bricks or when
by visual source changes
observation
Concrete Blocks: (Solid and Hollow)
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A) Raw materials and their inspection:
Terminology:
a) Concrete Blockshall be applied to concrete masonry unit having any external dimension greater than
the dimension of an ordinary brick and shall be of such size and mass that it can be handled by one man.
Moreover height of block shall not exceed either its length or six times its width. Concrete blocks shall
conform SANS.
b) Hollow Concrete Blocks: Concrete blocks having holes or cavities such that total solid material lies
between 50 – 75% of total volume of block, calculated by its external dimensions, shall be termed as
Hollow Concrete Blocks.
Both Solid and Hollow Concrete block shall be referred with respect to their external dimensions. Hollow
concrete block shall be of Grade A, Grade B or Grade C whereas Solid concrete blocks shall be of Grade
D as per SANS with the acceptance criteria as specified there in.
Visually, blocks shall be sound, have uniform texture and shall be free from cracks and other defects
which may impair its strength. The faces of concrete blocks shall be flat rectangular and opposite faces
shall be parallel as also all angles shall be 90o. Minor chipping resulting during handling shall be allowed.
Concrete blocks shall satisfy Dimensional Analysis Criteria, Block Density, Compressive Strength, Water
absorption test, drying shrinkage etc.
B) Acceptance Criteria:
Following procedure shall be adopted for acceptance of concrete block at site.
Readymade Concrete Blocks:
i) For the purpose of sampling, 20 blocks shall be chosen from every lot / consignment. (Consignment of
5000 blocks or part thereof of same grade and dimension shall be considered as a lot).
ii) Blocks selected, shall then be subjected to tests as described and acceptance of the blocks shall be as
per criteria mentioned therein.
iii) Concrete blocks shall bear identification mark of manufacturer as well as Grade of concrete.
iv) Concrete blocks over which plastering is required shall have rough textured faces.
Cast-in-situ Concrete Blocks:
i) Concrete used for making blocks shall not be richer than 1 part of cement by volume to 6 parts by
volume of combined aggregates.
ii) W/C ratio shall be strictly adhered to using electronically measuring device attached to mixing drum.
iii) Web marking in hollow blocks shall be clearly indicative of good workable concrete.
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iv) Blocks shall be properly compacted by vibro-compaction and finished by proper sizes without
breaking edges.
v) After de-moulding, concrete blocks shall be allowed to harden and then cured for a period of about 14
days by completely immersing in water or by covering with moist wet hessian cloth.
vi) Smooth concrete blocks which require plastering shall be given a rough texture on its faces with wire
brush, while concrete blocks are still green.
vii) After curing, concrete blocks shall be dried for a period of about 2 weeks, prior to their actual use.
Special checks on hollow concrete blocks:
Face shell thickness and thickness of webs of Hollow Concrete Blocks shall be checked as per following
table as per SANS
Sr. No. Nominal Block Width (mm) Face Shell Thickness (mm) Thickness of Web (mm)
1 100 or less 25 25
2 100 – 150 25 25
3 150 – 200 30 25
4 Over 200 35 30
Cellular Light Weight Concrete Block
A) Raw materials and their inspection:
Visual observations: CLC blocks shall be referred with respect to their external dimensions. Visually,
blocks shall be sound, have uniform texture and shall be free from cracks and other defects which may
impair its strength. The faces of CLC blocks shall be flat and rectangular. Opposite faces shall be parallel
and all angles shall be 90o. Minor chipping up to 25 mm resulting during handling in 5% of blocks
inspected shall be allowed.
B) Acceptance criteria:
For the purpose of sampling, 20 blocks shall be chosen from every lot received through consignment /
cast on site and they shall be visually inspected (Consignment / casting lot of 10000 blocks or part
thereof same grade shall be considered as a lot).
a) Blocks selected, shall then be subjected to tests as described and acceptance of the blocks shall be as
per criteria mentioned in SANS.
b) Factory supplied CLC Blocks shall bear identification mark of manufacturer as well as crushing
strength in Mega Pascal (MPa) or N/mm2.
Guidelines for inspection of Concrete Blocks (Solid and Hollow)
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Sr.
Description Mode of Inspection Acceptance Criteria Frequency
No.
Dimensional Field Test: Every
Analysis 20 blocks at random are checked. Consignment
1 Theoretical Vs Actual Length < +/- 5 mm
Theoretical Vs Actual Width < +/- 3 mm
Theoretical Vs Actual Height < +/- 3 mm
Average Block > 1500 kg / cum (Hollow blocks,
Density (3 Field Test Load bearing)
2 blocks out of Every
1000 - 1500 kg/cum (Hollow
20) Consignment
blocks, Non load bearing)
> 1800 kg /cum (Solid blocks)
Average External / Internal lab test 10% by weight Every
Water Consignment
3 absorption (3
out of 20
blocks)
Average External / Internal lab test > 2.8 MPa (Hollow load Every
Compressive bearing individual) Consignment
Strength
> 3.5 MPa (Hollow load bearing
average)
>1.2 MPa (Hollow non load
4
bearing individual)
>1.5 MPa (Hollow non load
bearing average)
>4.0 MPa (Solid individual)
>5.0 MPa (Solid average)
Average MTC / External Lab test < 0.10 % Once in
Drying every 50000
5 Shrinkage blocks or
change of
source
6 Visual Defects Field test Free from Minor cracks, Every
chipping in blocks not greater Consignment
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than 25 mm in depth
Guidelines for Inspection of Non Load Bearing CLC Blocks Grade 1 & Grade 2 Ref: SANS
Sr.
Description Mode of Inspection Acceptance Criteria Frequency
No.
1 Dimensional Field Test: Once in every
Analysis 12 blocks at random are 10000 blocks or
checked. change of
< +/- 5 mm source
Theoretical Vs Actual
< +/- 3 mm
Length
< +/- 3 mm
Theoretical Vs Actual
Width
Theoretical Vs Actual
Height
2 Average Block Internal Lab Test Not more than 1o00 kg /cum Once in every
Density (3 blocks Grade 1 & 2 10000 blocks or
out of 24) change of
source
3 Average External / Internal lab test Density Strength MPa Once in every
Compressive Kg/ cum G1 G2 10000 blocks or
Strength ( 6 out of change of
451-550 2 1.5
24 blocks ) source
551-650 4 3
651-750 5 4
751-850 6 5
851-1000 7 6
4 Average Thermal MTC / External Lab test Density Thermal Conduct Once in every
Conductivity ( 3 Kg/ cum W / mk 10000 blocks or
out of 24 blocks ) change of
451-550 0.21
source
551-650 0.24
651-750 0.30
751-850 0.37
851-1000 0.42
5 Average Drying MTC / External Lab test < 0.05 % for Grade 1 blocks Once in every
Shrinkage ( 3 out 10000 blocks or
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of 24 blocks ) < 0.10 % for Grade 2 blocks change of
source
6 Visual Defects Field test Free from cracks, right angle Once in every
edges satisfactory, chipping in 10000 blocks or
( all 24 blocks ) blocks not greater than 25 mm change of
in depth source
C) Nominal dimensions of CLC Blocks Ref: SANS:
Concrete block shall be referred to by its nominal dimensions. The term ‘nominal’ means that the
dimension includes the thickness of the mortar joint. Actual dimensions shall be 10 mm short of the
nominal dimensions (or 6 mm short in special cases where finer jointing is specified).
The nominal dimensions of the concrete block shall be as follows:
Length: 400, 500 or 600mm
Height: 200, 250 or 300 mm
Width: 100, 150, 200 or 250 mm
In addition, block shall be manufactured in half lengths of 200,250 or 300 mm to correspond to the full
lengths. The nominal dimensions of the units are so designed that taking account of the thickness of
mortar joints, they will produce wall lengths and heights which will conform to the principles of modular
co-ordination. Blocks of sizes other than those specified above may also be used.
Fly Ash – Lime Bricks
A) Raw materials and their inspection:
Fly ash – Lime Bricks, sometime referred as calcium silicate bricks shall conform to class 3.5 as
mentioned in SANS. Bricks shall be hand mould or machine mould. They shall be made from pulverized
fuel ash from power plant (Fly ash) conforming to grade I or grade II of SANS as major quantity, lime and
accelerator as a catalyst and then intergrading and blending it with other materials. Such a moulded
brick shall be well cured under different conditions of temperature and pressure.
Visually, bricks shall be sound, compact and uniform in shape. They shall be free from visible cracks,
warpage and organic matters. Bricks of 60- 90 mm height shall have a well-defined frog of 10 mm to 20
mm depth covering about 15% of surface area. However, bricks of 40-30 mm height need not be
provided with frogs. Bricks shall be marked with manufacturer’s identification mark or initials. Bricks
shall have smooth rectangular faces with sharp corners and show uniformity in shape and colour. Also
brick shall satisfy Dimensional Analysis Criteria, Water Absorption test, Wet Crushing Strength,
Efflorescence coverage test. Only lower class fly ash – lime bricks, to be used as partition walls.
B) Acceptance criteria:
Test for dimensional accuracy
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i) 20 whole bricks shall be selected at random from the truckload. All the bricks shall be arranged on a
level surface successively in a contact with each other and in a straight line.
ii) Overall length of bricks shall be measured in line. Also difference in maximum and minimum size of 20
bricks sampled shall be calculated.
iii) Similar procedure shall be adopted for width and height.
iv) Bricks failing in dimensional analysis, especially in width parameter shall not be used for construction
of external walls to limit plaster thickness, avoid cracking and de-bonding of excessively thick plasters.
v) Criteria for acceptance shall as per the following table,
Guidelines for inspection of Fly ash – Lime Bricks
Sr.
Acceptance
No Description Mode of Inspection Frequency
Criteria
.
1 Dimensional Field Test: Every
Analysis 20 bricks at random are chosen and Truckload /
placed on a plane horizontal surface Consignment
For 20 bricks lot:
Theoretical length Vs Actual length < +/- 80 mm
Theoretical width Vs Actual width < +/- 40 mm
Theoretical height Vs Actual height < +/- 40 mm
For individual brick ( out of 20 brick
lot)
Max. length of Brick sample VS Min < 10 mm
length of Brick sample
Max. width of Brick sample VS Min < 5 mm
width of Brick sample
Max. height of Brick sample VS Min < 5 mm
height of Brick sample
* All sides should be in right angle and
edges not broken.
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2 Average Water External / Internal lab test Not more than Every 10000
absorption 20% bricks or when
source changes
3 Average wet External / Internal lab test Not less than Every
Crushing 3.5 Mpa Consignment
strength
4 Efflorescence External lab test Not more than Every 10000
Coverage ‘Moderate’ as bricks or when
per IS by visual source changes
observation
TOOLS:
A. Trowels, Line Dori, Level Tubes, Plumb Bobs, Measuring Tape, Spirit Levels, Aluminium Straight
Edge, Right Angles.
B. Chipping tools, Mason Trowel, Mason hammer, Levelling thread, Mason Brushes, Mortar Boxes.
Procedure to be followed for Brick / Block Masonry:
Pre Masonry Checks:
1) Before starting masonry, it should be ensured that all electrical conduiting works should be complete
through beams.
2) Cleaning of slab surface should be done where masonry work to be carried out and centreline of brick
/ block work should be marked on the slab. Dimensional checking should be done for room dimensions
and diagonals.
3) Soaking of bricks in stack should be done by immersing in water or by sprinkling with water on the
previous day of laying. The blocks shall be slightly moistened from all sides by little sprinkling of water.
Excessive wetting of blocks shall be avoided.
4) Only required nos. of bricks / blocks should be carried to the work place to carry out the activity.
5) Saw dust / sand bags should be stacked over / around beam and column locations and unloading of
bricks / blocks at work place should be done over it to avoid damages due to unloading.
6) Stacking of bricks should be done near beams and column locations and maximum 100 bricks /
stacking of blocks weighing not more than 300Kg should be stacked over an area of 1 sq. m.
7) Concrete surface should be cleaned of all nails, embedded wooden pieces, etc. using wire brush
before layout for masonry.
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8) Adequate hacking of surface should be done to concrete surface (base slab as well as adjacent column
surface). An approved bonding agent (e.g. Hacked plast) may be applied to concrete surface in place of
hacking for bonding.
9) Sieving of sand should be done for mortar for masonry. Gradation of sand for use in masonry mortars
as per SANS is given for reference. If grading of sand falls outside the specified limits as above, the
required grading may be obtained by screening and / or blending together natural sand and crushed
sand having required size particles in appropriate quantities.
10) Line out for masonry work should be done before starting actual laying of masonry. First, slab
surface should be cleaned and applied with cement slurry and a layer of rich mortar. Over this, bricks
shall be laid. Checks for dimensions and right angle should be done as per drawing. Discrepancies in
dimensions shall be adjusted on site in consultation with site engineer to finalize lineout.
11) Scaffolding: - Scaffolding shall be double and shall be erected with steel sections or pipes of
adequate strength so as to be safe for construction operations. The contractor shall take all measures to
ensure the safety of the work and working people. Proper scaffolding shall be provided to allow easy
approach to every part of the work. Overhead work shall not be allowed. Making holes of any kind for
the purpose of supporting the scaffolding shall not be permitted. The scaffolding shall be sound and
strong to withstand all loads likely to come upon it.
During Masonry Checks:
1) Mortar for masonry should be mixed in desired proportions in M. S trays only. In absence of M. S
trays, mortar should be prepared in sunk of toilets or by creating a circular bund of bricks / blocks. This
should be done to avoid loss of cement slurry while preparing mortar. Batching of sand should be strictly
done by pharmas (measuring boxes).
2) Replacement of Ordinary Portland Cement by fly ash up to a percentage as approved by quality
department with respect to Cement strength/properties is recommended and may be done in mortars
for which mixing should be done in mechanical mixers only and the mortar shall be brought to work
place by wheel barrows and unloading should be done in M. S trays / sunk slabs / bunds at work place.
3) Crushed sand can be used individually or blending it with natural sand as per gradation requirement.
4) It is essential that proper water cement ratio is maintained in mix. After mixing, mortar should not
show excess bleeding water. Admixtures, if recommended, should be added in proper dosages.
5) First layer of brick work should be laid as per layout marked with position of frog upwards and first
layer of block work with a mortar of one grade higher. If necessary, first layer of block shall be laid with
concrete, so that all the subsequent layers can be laid in full block height and no cutting of blocks is
required while laying top course below beams. Bricks / blocks laid on top should be tamped for proper
bondage. Level adjustment should be done in the thickness of mortar bed so that top of laid course is in
perfect level. Spirit level should be used for the same.
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6) Subsequent layers of bricks / blocks should then be laid over first layers, care being taken so that each
layer is truly horizontal and joint thickness is not more than 15mm horizontal as well as vertical.
7) Use of mortar should be made within 90 minutes of preparation and any mortar which has set should
not be mixed with fresh mortar. Also it essential that water should not be added to increase workability
since it reduces strength of mortar. Instead use of plasticizer is recommended. While preparing mortar,
cement and sand shall first be dry mixed and then water is to be added in appropriate quantity.
8) Mortar should be dashed on column surfaces as work progresses for proper adhesion. Gap of 20 mm
shall be left between column surface and masonry. Use of trowel for filling gap between column surface
and masonry works should be avoided. Joints between column surface and masonry shall be filled with
rich mortar and then packed with 20 mm metal.
9) In a day’s work, brick/block work should not be constructed more than 1.2m height for 6”/9” walls
and 0.9 m height for 4” walls at the most. At the end of the day, joints (horizontal & vertical) should be
raked to a depth of 10 mm with the help of raking needle. Such brick/block work should be watered
within 12 hours of construction. Minimum curing period recommended is 7-10 days depending on type
of cement and climatic conditions.
10) Special precaution should be taken at the junction of 9” to 4” wall by properly interlocking bricks and
at the junction of brick and block walls.
11) Next day an RCC (M 15) band of 3” / 4” in height should be constructed over the brick / block work
(4” or lesser) laid earlier. This imparts additional strength to the brick / block work. Such bands need not
be provided for 6” and higher thickness of walls for normal room heights up to 3 m. It is recommended
to put 8 mm bars (2 nos.) within RCC bands and anchored properly in main walls / columns.
12) Local lintels should be cast before fixing door frames as per drawing with sufficient bearing on
masonry walls. Recommended bearing of lintels on masonry is 6” and anchoring of lintels to columns
should be done by drilling holes (minimum 4” deep inside columns) and thereafter filling the holes
inserting projecting bars from lintels into it and entire holes should be filled with epoxy based non-shrink
grout for proper bondage. Lintel bottom level should be checked accurately from finished floor level.
Shuttering, if cast on site for lintels, lofts and chajjas shall not be erected within 3 days of construction of
masonry.
13) In Hollow Concrete Block work, care shall be taken so that mortar doesn’t get filled in the cavities of
blocks to avoid unnecessary wastage of mortar.
14) It is important that in both Solid as well as Hollow Concrete Block Masonry works following is
attended to:
a) Top course at sill level and jambs of openings as well as top course touching beam or slab soffits are
constructed using Solid Blocks or with Hollow Blocks with cavities filled with M10 concrete.
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 109 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
b) For conducting through hollow blocks, the cores shall be filled with mortar at the location of
conducting for the purpose of chasing to required depth.
15) Fixing of sub frame is strongly recommended.
16) Bottom edge of brick / block work should be raked and 15 mm portion away from walls should be
filled with lean mortar for expansion of tiles.
17) Door frames should be preferably be fixed while masonry is being constructed, to avoid gaps
between door frame and masonry surface.
18) It is recommended to use very heavy holdfasts for door frames and hence from practical point of
view recommendation for holdfast are; 4 nos. for external door and 3 nos. for internal doors each.
Holdfast should be of MS (Galvanized or painted with red oxide), 350 mm long 40 mm wide and 2 mm
thick and fully embedded in concrete / screwed to columns.
19) When door frames are to be fixed after masonry construction, temporary brick pieces should be
filled to the entire length of holdfasts and to the height equal to two courses of bricks at the positions of
holdfasts during construction of masonry and while fixing door frames, holdfasts should be anchored
into required positions by filling the surrounding gap by 1:2:4 concrete using 10 mm downgraded coarse
aggregate. Recommended positions of holdfasts are 300 mm each from top and bottom and third at
centre. Fixing of holdfasts to columns should be done by drilling and nailing alternately on either side.
Gap between door frames and masonry surface should be filled with rich mortar with fibres or non-
shrink mortar.
20) If door frames are fixed along with masonry construction, it is strongly recommended that door
frames fixing should be done by taking level pads (spots) of plaster on masonry walls whenever door
frame is flush with plaster. Door frames shall be fixed so that it is parallel to room dimensions.
21) Door frames should be checked for any cracks, bends, plainness, depths of rebates as per drawing
and door frames showing deviations beyond repairs should not be used. Minor bends in door frames
should be corrected out by inserting wedges.
22) It is must that all openings other than doors should be provided with PCC bands.
23) One more level correction should be carried out at the top of PCC / RCC band.
24) Above PCC / RCC band, masonry courses are laid in the similar way as explained earlier. However
masonry work should not continue up to soffits level of beams above. The reason for this being,
shrinkage which occurs within the masonry already constructed. So it is recommended to leave a gap of
one layer of bricks with 25 mm gap below beam bottom while constructing masonry for the same.
25) After a gap of 7 days, top most layer of masonry should be laid using non-shrink mortar as a filler
material between masonry and RCC beam bottom to avoid any subsequent gap formation due to
shrinkage. Also 20 mm metal packing should be done within the joint between masonry top and beam
bottom.
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26) For masonry works, which requires stoppage for any reason whatsoever, a stepped joint at
approximately 45º should be provided as a horizontal joint for proper bondage of bricks later. For cross
wall connection bricks should be left projecting at every third course in the main wall for joining to cross
wall later.
27) It is recommended that for 4” and less partition walls, electrical switch boxes should not be placed
back to back since while making grooves from both sides for embedded electrical conduiting, the
masonry wall gets weakened.
28) Care shall be taken to see to it that vertical mortar joints in successive brick layers are staggered.
29) For box type aesthetic features, which are closed from outside, a small opening in masonry shall be
kept during construction. Inside face of box shall be plastered and bottom portion shall be applied with
water proof cement sand coat and finished with rounding. The base coat shall be given slope outwards
and provided with minimum two spouts to drain off water. Mortar droppings within the box shall be
removed from the openings provided.
30) During masonry work, strong supervision is required for achieving good workmanship and quality
work.
Post Masonry Checks:
1) Date of construction (DOC) should be marked on masonry to monitor curing. Curing shall be carried
out by wetting the brick masonry for 7-10 days depending on type of cement and climatic conditions. In
hot weather, curing shall commence within 12 hrs. of construction of masonry. Care should be taken
that the masonry surface should remain moist throughout the period of curing.
2) It is recommended that chases in masonry should be made using round wheel cutter with light
chiselling so that masonry works is not damaged. Also chases in masonry lesser than 6” thick should be
done after plastering work is complete.
3) Depth of chases should be only 5 mm more than diameter of electrical conduits to be embedded.
Excessive chasing weakens the masonry. No chasing shall be done in RCC structural member.
4) After conduits are put in chases, chases are rendered with non-shrink grout with fibres and chicken
mesh is fixed over it.
5) In case of any major defects such as major differences in level, plumb of masonry, dismantling shall be
carried out as per instructions from QA Department
Tolerances:
Following checks should be given once brick masonry construction is over:
1) Horizontal / Vertical joint thickness should be uniform, truly horizontal or truly vertical and not more
than 15 mm thick.
2) Tolerance limit for coarse level should be 10 mm maximum.
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3) Raking of joints – minimum 10 mm deep.
4) Checking plumb of walls:
Non plumb face of masonry should not be out of plumb of more than 10 mm.
Plumb face of masonry should not be out of plumb by more than 5 mm.
(IS specifies maximum 6 mm tolerance for a storey of height 3 m and 12.5 mm for entire height of
building more than single storied building)
5) Checking room dimension: Tolerance kept for diagonal distance is 10 mm.
6) Checking qualities of bricks on masonry walls: Over burnt bricks should be limited to 10%. Bricks
showing high variation in dimensions should be limited to only 10% of walls under observation.
Records :
Reference Documents :
ITP Reference No
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METHOD STATEMENT FOR
INTERNAL PLASTERING WORKS
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METHOD STATEMENTS
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Page 113 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
SR. EFFECTIVE REV. MSS MANAGER MSS PROJECT CLIENT
CLIENT QA/QC
NO. DATE NO. QA/QC MANAGER SUPERVISOR
INTERNAL PLASTERING WORK
General:
Cement:
For internal plastering, following checks are important.
1) Cement shall be OPC 43 Grade or PPC and not more than 8 weeks old.
2) Cement shall be free from lumps.
Natural Sand:
Sieving of sand should be done for mortar for plastering. Gradation of sand for use in plaster mortar as
per IS 1542 is given below for reference.
SIEVES Percentage passing by mass
10 mm 100
4.75 mm 95 to 100
2.36 mm 95 to 100
1.18 mm 90 to 100
600 microns 80 to 100
300microns 20 to 65
150 microns 0 to 15
If grading of sand falls outside the specified limits as above, the required grading may be obtained by
screening and / or blending together natural sand and crushed sand having required size particles in
appropriate quantities.
Silt content should not exceed 8 % by volume (3% by weight) and fineness modulus may vary from 1.2 to
2.2. However it is preferable to have minimum Fineness Modulus around 1.5.
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Crushed / Washed Sand:
For washed / crushed sand following checks are important:
1) Fineness Modulus can vary from 1.2 to 2.2, however it is preferably to have minimum Fineness
Modulus around 1.4.
2) If grading of crushed sand falls outside the specified limits as above, the required grading may be
obtained by screening and / or blending together natural sand and crushed sand having required size
particles appropriate quantities.
Fly ash:
For internal plaster works, following checks are important:
1) Sources of fly ash must be standardized as per test reports and fly ash must meet the requirements of
SANS. Further retention on 45 micron sieve after wet sieving should be less than 20%.
2) Fly ash should be free from lumps.
3) If mortar mix design is made using fly ash, mechanical mixer shall be used while preparing mortar.
Water:
Construction water must meet the requirements of SANS.
TOOLS:
A. Trowels, Line Dori, Level Tubes, Plumb Bobs, Measuring Tape, Spirit Levels, Aluminium
Straight Edge, Right Angles.
B. Chipping tools, Mason Trowel, Mason hammer, Levelling thread, Mason Brushes, Mortar
Boxes.
Procedures to be followed for Internal Plastering Work:
Pre Plastering Checks.
1) It is recommended to carry out external plastering before internal plastering to prevent rapid drying
and shrinkage of internal plastered surfaces.
2) Minimum gap of 7 days shall be maintained between completion of brick masonry and
commencement of internal plaster application.
3) For application of cement sand plaster, thorough wetting of masonry should be done 2 days before
commencement of plastering. The day prior to plastering, masonry surface shall be left to attain
Saturated Surface Dry (SSD) condition.
4) Proper scaffolding shall be provided to allow easy approach to every part of the work, take all
measures to ensure the safety of the work and working people. In no case, holes in masonry should be
done for supporting scaffolding.
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5) Level pads of size not less than 2” x 2” shall be made on the walls and if required on ceiling also to
serve as finished reference level surface. The distance between level pads shall not exceed 6’ in any
direction so that their surface alignment can be checked with the help of aluminum straight edge.
6) Level pads shall also be checked for vertical alignment with the help of plumb bob, for right angle with
the help of right angle and for diagonal dimension of room with the help of tape.
7) At place of work where sufficient natural daylight is not available, artificial light shall be made
available.
8) In case of level differences in adjoining surfaces, the same shall be made up before fixing of chicken
mesh / fibre mesh.
9) Chicken wire mesh shall be fixed at the joints of BBM and concrete. Chicken wire mesh shall be 20
gauge, with 12 mm hexagonal holes and minimum 6” wide in the form of strip.
10) Chicken mesh after stretching shall be fixed at 9” intervals by drilling/punching holes in masonry and
concrete and then nailing with metal washers. Minimum overlap for chicken mesh shall be 4”.
11) Instead of chicken mesh, fibre mesh can be used. Fibre mesh shall be stretched over the joints and
fixed to walls with the help of mortar spots at every 9” interval. Joints of brick /block & RCC junction
shall be applied with non-shrink mortar e.g. CNS 50 or equivalent.
12) Surface preparation
All the nails, binding wire, concrete projections and wooden piece shall be removed from concrete
surface and brick masonry.
All the dust, oil spots, and green algae, if any, shall be cleaned from concrete and brick masonry
surface with the help of wire brush.
13) It is recommended that all concrete surfaces where plaster is to be applied shall be applied with
bonding agent. Bonding agents shall be applied as per instructions of manufacturer. If bonding agent is
used, hacking of concrete surface shall be avoided.
14) Concrete surface should be roughened for proper bonding. Hacking should be done @ 1” c/c.
(Minimum 60 to 65 hacks per Sq. ft.)
15) All electrical chases shall be properly rendered with non-shrink grout and application of chicken /
fibre mesh over it and cured properly for 7 days before starting any type of plaster or curing compound
can be applied for the same.
16) All the conduit drops shall be checked and concealed with plaster. All the ceiling points and wall
points shall be checked for level and dimensions as per drawing or as per client’s requirement if any.
17) It shall be ensured that all electrical boxes are protected with plastic sheet packing before plaster.
18) Wooden / natural stone frame used for doors / windows should be protected before plastering.
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19) It shall be ensured that all plumbing points are in proper location, line and level as per drawing. All
plumbing chases shall be properly rendered with non-shrink grout and application of chicken / fibre
mesh over it and cured properly for 7 days before starting any type of plaster.
During Plastering Checks:
Cement Sand Plaster
1) Mortar for plaster shall have minimum strength 3.5 MPa. For this 7.07 cm cubes shall be casted of
cement sand mortar and shall be tested after well curing for 28 days.
2) Cement sand mortar shall be used as specified and it is recommended to carry out batching of sand
by weight (batching if mix design for mortar is made)
3) In case, volume batching is to be done, calibrated boxes (pharmas) of required correct sizes shall be
used. It is recommended to apply 1:4 mortar for side wall and 1:3 mortar for ceiling in the absence of
any specification. PPC or OPC-Fly ash combination is recommended, since reduced water demand and
reduced heat of hydration reduces shrinkage and thermal cracks respectively. Also PPC or OPC-Fly ash
combination has better resistance against chemical and sulphate attack.
4) Water cement ratio shall be as per mix design (If mix design is available) or such as to obtain mortar
mix of optimum workable consistency.
5) Mortar required for Plaster work shall preferably be mixed in half bag or full bag mechanical mixer
and shall be carried out to required floor with the help of hoist and wheel barrows and unloaded in MS
tray/bund and thereafter it shall be carted to actual work place.
6) While preparing mortar in mixer, cement and sand shall first be dry mixed and then water is added to
it in appropriate quantity. Wet mix shall then be mixed thoroughly in mixer for a minimum period of 3
minutes. Fibre of 6mm length shall be used as specified by Q. A. Department. Plasticizers of approved
make may be used as specified.
7) For small works, mortar can be made by hand mixing in MS tray / sunk / bunds. After dry mixing, wet
mixing by hand shall be carried out for a period of at least 5 minutes.
8) The mortar mixed shall be utilized within 90 minutes of preparation and the same shall be used
before recommended setting time of cement mortar, if retarders are used.
9) While applying plaster on walls, empty cement bags shall be placed on floor near walls and
rebounded mortar fallen on bags shall be put back into mixed mortar before it sets and 10% additional
cement should be added in that mix and remixing should be done before its use.
10) Use of dry cement shall be limited to finishing of edges only.
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11) For internal plaster, average thickness of plaster shall not be less than 12 mm and not more than
15mm. The plaster above 15 mm thickness shall be done in 2 coats. Proper roughening to first coat shall
be done before application of second coat for proper bonding and shall be cured for at least 3 days.
Bonding chemicals can be used between the two coats for proper bonding.
12) Proper checking and supervision for plumb, line, right angle, measurement of openings after
application of plaster should be done by site supervisor / engineer.
13) Thickness above 20 mm, if required shall not be built up in single operation. Thickness will be built
up gradually using a combination of chicken mesh, fibre mesh, etc.
14) Electrical switch boxes shall be perfectly in line with plaster.
Post Plastering Checks:
Cement Sand Plaster:
1) After plastering work is complete, neeru / sanla shall be applied on plastered surface within 2 hours
till the plaster is green and mason shall trowel the neeru / sanla surface to get smooth finish. Thickness
of neeru shall not be greater than 1.5mm and neeru shall be cured.
2) It is recommended that 5 mm deep grooves shall be made (to limit the shrinkage cracks) on the
finished neeru / sanla surfaces. Such grooves shall be spaced at 5’ both horizontally and vertically. After
a period of 4 weeks, these grooves shall be filled with plaster of paris to ensure a uniform surface. It is
applicable for back coats also.
3) Window frames, sills, door frames, electric switch boxes, fan boxes, taps, railings, plumbing fittings,
glass etc. shall be cleaned immediately.
4) Wherever wall tiling is required, roughening of plastered surfaces shall be carried out for better
bonding of tiles. In such a case, no application of neeru / sanla / POP / gypsum shall be made on the
plastered surfaces.
5) Plaster above the floor slab shall be cut in level to a height equal to height of skirting for fixing skirting
tiles.
6) In toilets, plaster shall be cut at 300 mm above FFL to accommodate base coat for water proofing.
7) Date of plastering shall be clearly marked on the plastered surfaces to monitor curing process.
8) Curing shall be done so as to keep plastered surface continuously wet for a period of 7-10 days
depending on type of cement and climatic conditions.
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9) Curing shall be done carefully, by gently application of water on top of wall surface, so that water rolls
down smoothly over plastered surface. Spraying of water jet with high pressure for curing shall be
avoided since it will peel off the neeru / sanla.
Tolerances allowed in Internal Plastering Work:
Type of Defect Tolerance
Plumb of pillars / columns 2 mm
Difference in right angle measured by 3-4- 5 3mm in 5’ length
method
Room dimensions (Length / width) 20 mm
Undulations in ceiling / wall surfaces Nil
Jamb sizes 3 mm
Non-uniformity in wall plaster Nil
Opening sizes (width / height) 5 mm
Defects in finishing of edges, offsets, corners, Nil
jambs and openings
Window / Opening sill finishing As per drawing
Visible cracks in plaster Nil
Delamination in plaster Nil
Records :
Reference Documents :
ITP Reference No :
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Page 119 of 864
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MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
METHOD STATEMENT FOR
EXTERNAL PLASTERING WORK
SR. EFFECTIVE REV. MSS MANAGER MSS PROJECT CLIENT
CLIENT QA/QC
NO. DATE NO. QA/QC MANAGER SUPERVISOR
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EXTERNAL PLASTERING WORK
General:
Cement:
For external plastering, following checks are important.
1) Cement shall be OPC 43 Grade or PPC and not more than 8 weeks old. 53 Grade if used shall be
adequately blended with fly ash. PPC or OPC-Fly ash combination is recommended since reduced water
demand and low heat of hydration reduces shrinkage and thermal cracks.
2) Cement shall be free from lumps.
Natural Sand:
Sieving of sand should be done for mortar of plasters. Gradation of sand for use in plaster mortar as per
IS 1542 is given below for reference.
IS SIEVES Percentage passing by mass
10 mm 100
4.75 mm 95 to 100
2.36 mm 95 to 100
1.18 mm 90 to 100
600 microns 80 to 100
300microns 20 to 65
150 microns 0 to 15
If grading of sand falls outside the specified limits as above, the required grading may be obtained by
screening and / or blending together natural sand and crushed sand having required size particles in
appropriate quantities.
Silt content should not exceed 8 % by volume (3% by weight) and fineness modulus may vary from 1.2 to
2.2. However it is preferable to have minimum Fineness Modulus around 1.5.
Crushed Sand:
For external plastering, following checks are important:
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1) Fineness Modulus can vary between 1.2 to 2.2. However it is preferably to have minimum FM around
1.4.
2) If grading of crushed sand falls outside the specified limits as above, the required grading may be
obtained by screening and / or blending together natural sand and crushed sand having required size
particles in appropriate quantities.
Fly ash:
For internal plaster works, following checks are important:
1) Sources of fly ash must be standardized as per test reports and fly ash must meet the requirements of
IS 3812. Further retention on 45 micron sieve after wet sieving should be less than 20%.
2) Fly ash should be free from lumps.
3) If mortar mix design is made using fly ash, mechanical mixer shall be used while preparing mortar.
Water:
Water must meet the requirements of IS 456:2000 and should be tested at a third party laboratory to
check the compliance before use.
Admixtures:
For admixture following checks are important
Brand and type of admixtures must be approved & standardized
Density and chloride content should be checked before approval.
Revalidation of mix design shall be done in case of any change in brand or type of admixture.
TOOLS:
A. Trowels, Line Dori, Level Tubes, Plumb Bobs, Measuring Tape, Spirit Levels, Aluminium Straight
Edge, Right Angles.
B. Chipping tools, Mason Trowel, Mason hammer, Levelling thread, Mason Brushes, Mortar Boxes.
Procedures to be followed for External Plastering Work:
Pre Plaster Checks:
1) Minimum gap of 7 days shall be maintained between brick masonry and external plaster.
2) Sequence of plastering shall be decided in advance. Joints of plaster shall be kept on centre of RCC
members such as beams / columns.
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3) It shall be ensured that scaffolding material to be used for the plastering should preferably be double
scaffolding. H- Frames or equivalent is recommended for the same. Both steel scaffolding as well as
wooden scaffolding is applicable up to 12 to 15 storey height. For larger heights, scaffolding shall be
designed from the designer and the same shall be used.
4) No holes shall be made in masonry for supporting scaffolding.
5) Bulges from concrete surfaces on external beams shall be chipped of so as to bring entire masonry
surface as well as outer surface of members in one line.
6) Joints between masonry and concrete members shall be filled with non-shrink mortar e.g. CNS – 50 or
equivalent or rich cement sand mortar in proportion 1:3 with fibre (polypropylene/ polyethylene) added
to it, 2 days in advance of starting of plastering and then cured for next 2 days till external plastering
work starts.
7) Curtain cloths or plastic sheets may be provided on external sides to prevent rapid drying and
shrinkage cracks of plastered surfaces due to wind or sunlight.
8) Pegs are driven diagonally at the corner edges on each floor starting from the top most floor of the
plastering area and line dori shall be fixed on pegs keeping it fully stretched.
9) Similar line dori stretched over entire surface at 6’ distance apart horizontally by driving pegs at every
floor. Line dories shall also be stretched horizontally at 6’ distance apart vertically to form a grid.
10) In addition, line dories also stretched horizontally as well as vertically along the sills, soffits and
jambs of openings, windows, ventilators , chajjas, and any projections kept for architectural effects,
11) Level pads of size not less than 2”X2” in size at 6’ c/c (i.e. at every vertical line dori.) both
horizontally and vertically shall be made on the wall to serve as reference level surface for base coat.
Levels pad shall be checked for plumb and right angles.
12) Drain spout in toilet and sunk shall be fixed.
13) Plumbing pipe holes shall be made in masonry, diameter of hole being 1” more than the pipe
diameter all round.
14) All terrace outlets (bends) as well as other plumbing outlets shall be placed within the holes, and
holes shall be renders with non-shrink grout.
15) Chicken mesh /fibre mesh /expanding metal shall be applied on joints of Brick / Block Masonry and
concrete. Chicken wire mesh shall be of 20 gauges, with 12mm hexagonal holes and minimum 6” wide in
the form of strip, Chicken mesh after stretching shall be fixed at 9” intervals by drilling / punching holes
in masonry and concrete and then nailing with metal washers. Minimum overlap for chicken mesh shall
be 4”
16) Surface Preparation
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 123 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
All the nails, binding wire, concrete projections, and wooden pieces shall be removed from concrete
surface and brick masonry.
All the dust, oily spots, and green algae, if any, shall be cleaned from concrete and brick masonry
surface using wire brush.
17) RCC / PCC coping for all sills and parapet tops shall be completed before commencement of external
plaster.
18) Masonry chiselling for electrical conduits or any other purpose shall be sealed with non-shrink
material with chicken mesh fixed over it, well before plastering of the surface.
19) The brick masonry shall be wetted thoroughly from outside on the day prior to day of application of
external plaster so that masonry surface is moist at the time of external plaster.
During Plaster Checks:
1) Mortar for plaster shall have minimum strength 3.5 MPa.
2) Cement sand mortar shall be used as specified and it is recommended to carry out batching of sand
by weight as per mix design.
3) In case volume batching is adopted, calibrated boxes of required correct sizes shall be used. Batching
shall be done as per recommended proportions in mix design.
4) Mortar required for plaster work shall be mixed in half bag or full bag mechanical mixers only.
5) While preparing mortar mix, cement, fly ash and sand shall first be dry mixed and then water is added
to it in appropriate quantity. Wet mix shall then be mixed thoroughly in mixer for a minimum period of 3
minutes. Fibre, if added in mortar shall be well separated by hand before putting them in rotating drum.
6) Water cement ratio shall be such as to obtain mortar mix of optimum workable consistency.
7) Water-proofing compound shall be added to mortar in adequate quantity as recommended by water-
proofing compound manufacturer. If water-proofing compound is in powder form, the same shall be
added to mortar during dry mixing of mortar and if in liquid form, the same shall be added to water
during wet mixing of mortar.
8) Mortar shall be used before initial setting time of mortar which is approximately 90 minutes.90utes of
9) External plaster shall be applied in two coats. Thickness of first coat shall not exceed 15 mm.
10) Empty cement bags / plastic sheets shall be kept on ground near the face of building and rebound
mortar collected on bags shall be poured in the mixer for reuse by adding 10 present extra cement. The
entire process shall not exceed 90 minutes.
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
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DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 124 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
11) In no case, joint of external plaster shall be kept on parapet wall, since that joint is highly susceptible
for seepage of rain water through parapet wall and ultimately to the rooms below. Parapet top plaster
shall continue at least 1’ inside the terrace.
12) Thickness of plaster on parapet top shall not exceed 20 mm and plaster top shall be given slope 15
mm inside to drain off rainwater inside the terrace.
13) First coat of plaster shall be sufficiently roughened for bonding of second coat over it.
14) First coat shall then be cured for minimum 3 days to maximum 5 days and then finishing coat shall
be applied over first coat.
15) If the time gap between application of first coat and second coat exceeds 5 days, cement slurry shall
be applied over first coat before applying second coat. Instead bonding agent as approved by QA/QC
Department can be applied for the same.
16) Grills, wherever provided, shall be fixed prior to application of second coat.
17) Bonding agent shall be applied to horizontal joints of first coat and finishing coat for proper
bondage. It prevents seepage of rainwater through horizontal joints. Horizontal joint as well as vertical
joint should be strictly kept on RCC members.
18) Thickness of second coat shall not exceed 8 mm and the same shall be finished as per requirement.
19) Grooves, if any, shall be of uniform depth and width throughout.
20) Finishing coat shall be applied in such a way that all vertical lines of windows, balconies, common
dividing walls shall match at all levels. Also sill and soffit levels of openings / windows / ventilators at any
floor shall be in one line.
21) Window reveals (external horizontal portion of window sill) shall be given outward slope to drain out
the rain water.
22) Drip moulds (Pani Patti) shall be provided to all the chajjas as well as projections. Pani Patti shall be
at 5 mm thickness and 35 mm in width or as per details given in the drawing.
23) Chajjas shall project minimum 6” beyond the window openings on both sides. If the drawing does
not show such projections, then such requirement shall be posed before the concerned architect and
work shall proceed with his suggestions or alterations.
24) Chajjas top plaster shall be rounded to merge inside the external plaster to prevent ingress of rain
water providing cut patti or as specified on drawing.
25) All external ornamental features shall show equal offsets, line, level, right angles etc.
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MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
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METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 125 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
26) In exceptional cases, where extra thickness of plaster is required (2” to 3”), the same shall be applied
in 2 to 3 layers, with proper anchoring by nails / chicken mesh / expanded metal etc.
Post Plaster Checks:
1) Wherever tiling is to be done at a later stage, roughening of plastered surfaces shall be carried out for
better bonding of tiles.
2) Window frames, sills, door frames, electric switch boxes, taps, plumbing fittings, glass etc. shall be
cleaned immediately.
3) Date of plastering shall be clearly marked on the plastered surfaces to monitor curing period.
4) Curing of final coat shall be done, so as to keep plastered surfaces continuously wet for a period of 7-
10 days depending on type of cement and climatic conditions.
Value added Parameters / Cost affecting Parameter:
1) Pure sand bags or equivalent can be used in place of river sand. It has advantages over river sand such
as weigh batching and volume batching can be done as required. Also graded sand will give less wastage
and easy storage & stacking can be done as required. The mix proportion with graded sand
recommended by manufacturer is (1:6) which is cost effective as compared with river sand.
2) Cement mortar in river sand is highly recommended to be used for the first coat (1:6) and richer
mortar for second coat (1:4).
3) The cement mortar mix used in plastering of duct (wall having plumbing/drainage pipe lines) should
be (1:4) for first coat as well as second coat and water proofing admixture is highly recommended for
the same.
4) Fibre are preferred to be used in first coat to reduce the rebound losses, shrinkage and prevent
development of crack formation over plastered surface.
5) Water proofing compounds used in plaster works will reduce permeability and give waterproof coat
over plaster surface. It is very essential especially in case of dead walls and long walls with lesser
openings.
6) Liquid polymer modified mortar can be used for plasters. It has added advantages such as enhanced
cohesion & adhesion, water repellence and strength. It reduces the rebound loss and increase the rate
of application of the plaster. It reduces the requirement of water for curing. It also reduces the time the
application of external plaster if second coat applied as soon as the first coat set. That means both the
coats can be done in same day and cured simultaneously.
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 126 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
7) It is recommended to use bonding agent to all joints of plasters (horizontal or vertical) to avoid
leakages through joints in future.
8) Sponge finish plasters are cost effective but uniformity in texture will not be maintained where as
gudgudi coat finish over plaster is comparatively costly but it gives uniformity in texture and has better
resistance to weathering effect.
9) It is recommended to carry out external plastering before internal plastering to prevent rapid drying
and shrinkage of internal plastered surfaces.
10) It is essential to provide curtain cloths (hessian cloth curtain or plastic sheets curtain) on external
sides to prevent rapid drying of plastered surfaces due to wind and sunlight.
Tolerances: Refer QA card for external plaster.
Type of Defect ( By visual Observation ) Tolerance
Finishing and visible defects in plumb /right angles Nil
(Horizontal/Vertical)/edges/offsets/jambs
Undulations on wall surfaces Nil
Cracks at masonry and concrete joints and on Nil
parapet top
Visible difference in level of parapet top Nil
Difference in level of grooves Nil
Efflorescence Minor
Top surface of cornice/chajjas Made Round
Edges (vertical and horizontal) of openings / In perfect line for each floor when viewed
windows / ornamental features from outside
Windows / ornamental features As per drawing
Inspection Record :
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
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DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 127 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
Reference Documents :
ITP Reference No :
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
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DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 128 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
METHOD STATEMENT FOR
FALSE CEILING (GYPSUM BOARD)
SR. EFFECTIVE REV. MSS MANAGER MSS PROJECT CLIENT
CLIENT QA/QC
NO. DATE NO. QA/QC MANAGER SUPERVISOR
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PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 129 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
GYPSUM WORKS
1. Objective :
This work procedure enumerates the scope of Gypsum work to be executed in the buildings as
specified in the approved drawings and at places when instructed by the Engineer-in-charge as per
approved specifications.
2. Applicability :
This procedure is applicable to the Gypsum work for Main & Substation Buildings & relevant
structures.
3. Reference Document :
a. Tender Specifications
b. Drawings
c. Manufacture’s Specifications
d. Client preferred Standard Codes
4. Equipment’s :
1. Related “Good for Construction” drawings
2. Plumb bob
3. Spirit levels 3m
4. Right angle
5. Measuring tape
5. Material:
1. 6.4 mm Rhino gypsum plaster board or similar any brand.
2. Rhino 75mm cornices & nailed.
3. H-type pressed steel jointing strips horizontal ceilings.
4. 380 x 380 mm sawn softwood brandering.
Procedure:
Material handling and stacking
Generally two men will be required and this will reduce the risk of damage to the boards. When off-
loading manually boards must always be carried on edge.
The boards should always be stored in a dry & covered place, sheltered from rain. They should be
supported on wooden battens, to avoid dampness from floors. These battens should not be more
than 45 cms apart on a flat surface. Gypsum board should never be stacked on edge for long periods
as this can cause deformation.
Cutting
Gypsum boards can easily be cut either longitudinally or transversely. A cut should be made in the
face side of the board by means of a retractable knife. A line may be ruled prior to cutting, or with
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MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
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METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 130 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
practice. The rule may be drawn down the board at the required distance from the edge whilst the
board is scored with a knife at the end of the rule. The board should then be pressed with both hands
and the gypsum core will break in line with the cut in the side face. The board should then be turned
over and the other side paper be cut with the knife.
Sawing
Gypsum board may be cut using a normal saw. A fret saw or an electric tool may also be used for
cutting of curves. When large quantities of board are to be cut, the use of a circular handsaw is
advisable.
Making holes/cut outs
Electrical or manual carpenters tools may be used for making cut outs. Drills should be used when
making holes for electrical installations. For holes of a diameter less than 50mm a high-speed still drill
gives a better result.
Planning
The edges of the board can be pared off using a plane. A file may also be used to level off any
irregularities, which may remain after cutting. The edges of both paper faces may be trimmed up if
necessary using fine sandpaper.
Bending
Gypsum board may also be used to line curved areas. The curvature radius will be 60cms for 9.5mm
Gypsum board. Both sides of the Gypsum board should be sprayed with water until they are damp.
The board should then be bent very slowly and carefully, and fixed into position. Before jointing, the
boards should be completely dry.
Process of Jointing & Finishing
1st application-- Embedding of paper tape into joints by using taping knife.
2nd application -- After first application is dried. Second finishing coat is applied
3rd application -- Final finishing coat application followed with topcoat.
Work procedure:
1. Ceiling
Suspended Ceiling
Grid Ceiling
2. Jointing and Finishing
TOOLS USED FOR GYPSUM WORK
Taping Knife
100 mm wide taping knife, flexible steel bladed knife for embedding joint tape.
Applicator
200 mm wide rigid bakelite blade with plastic grip for applying Gypboard jointing compound.
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
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TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 131 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
Electric Drill with Clutch Attachments
Converts standard electric drill to a power screwdriver suitable for fixing Gypboard to metal frame
system.
Crimping Tool
Punches and locks together 0.55 mm sections. Used for crimping at the base and head of the
partition or separating wall. Also used in Gypboard steel beam and column encasement system.
Anchor Fastener
It is of 12 mm diameter and 38mm long expandable aluminium alloy fastener. It is used to hold, the
suspended ceiling at 1220 mm in both directions. Each rawl plug can take load of up to 25 kg.
Connecting Clip
2.64 mm diameter spring steel wire made to suit and hold the ceiling section & intermediate channel
together to form a regular frame.
Screws
Drywall screws are self-drilling and self-tapping with counter sunk Philips head. These are
either oxidized or galvanized to avoid rusting.
Joint Paper Tape
A paper tape of reinforcing tapered edge joints and internal angles in both manual and mechanical
jointing systems. It has a center crease, chamfered edges and slit perforation in four rows. Supplied in
120 mtr x 53 mm rolls, ten rolls to a pack.
INSPECTION METHODOLOGY FOR QUALITY ASSURANCE
1. Check for line level plumb using the same tools used for block masonry.
2. Ensure the joints are recessed to 4 mm to 5 mm at the joints to the width of the fiber mesh
3. Ensure fiber-mesh/ paper tape is fixed for all joints and horizontal corners
4. Ensure gypsum corner beads are fixed at all vertical joints
5. Gap between two boards should not exceed more than 5 mm.
6. Ensure joints of two Gypsum boards are treated with only jointing compound of Indian Gypsum
Limited and not Plaster of Paris POP.
7. Ensure horizontal bracings are provided for GI frame in partitions of more than 3m high.
8. Ensure horizontal bracings are provided for GI frame in slender partitions or places where switch
plates, wall mounted fixtures, etc are fixed.
9. Avoid gypsum walls and partitions in water prone areas like toilets, pantry kitchen etc.
10. The dust from sanding at the joints should be removed either using soft cloth or soft broom
before start of painting works.
11. Ensure fisher plug with 35mm long GI screws are used for perimeter channel fixing and black
star screws of 25mm are used for fixing boards.
12. For prevention of cracks at joints ensure that:
Paper tape is used and pressed properly at the joints
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'V' grove is cut & filled properly at square edge joint
Drywall screws are properly driven with clutch attachment, arresting movement between
board & frame
Vibrations of A.C. duct/ generators are not passing onto the ceiling/ partitions
1. Inspection Record :
2. Reference Documents :
3. Inspection Test Plan :
METHOD STATEMENT
FOR
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MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
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Page 133 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
INTERNAL PAINTING WORK
SR. EFFECTIVE REV. MSS MANAGER MSS PROJECT CLIENT
CLIENT QA/QC
NO. DATE NO. QA/QC MANAGER SUPERVISOR
INTERNAL PAINTING WORK
General
Paint is combination of resins, pigments, binders (natural or synthetic), additives and solvents.
Specifications: Plascon-Evans
There are various types of paints depending upon the material, base etc. Accordingly the paint is
classified as mentioned below:
Material:
Filler materials for undulation, cracks, & smoothening
Alkali resistant primer
PVA acrylic emulsion paint
Base:
Oil based paint
Basic Properties of paint:
Durability
Breathe ability
Dust / dirt proof
Washable
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PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
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NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
Weather Proof
Raw Materials, their Inspection and Acceptance
A) Paints:
1) Type of paint shall be appropriate as per Plascon-Evans specifications.
2) Other types of paint which are delivered in cans / drums shall be checked for following details on
The packing:
Manufacturer’s name
Batch and lot number
Date of manufacturing
Expiry date
ISO / ISI mark
Special instructions by manufacturer’s for proper mixing and application as also to maximize product
performance and minimize wastage.
ECO mark (eco-friendly) (if any), stating criteria for which ECO mark is obtained.
Percentage of toxic element like Lead, Cadmium and Chromium (if present)
4) Colour code as well as colour shade of paint shall be matched with that mentioned in the purchase
order before acceptance.
5) Paint cans after opening shall not give out foul odour.
6) Paint Manufacturer’s literature should clearly mention that following tests have been carried out in
the laboratory and shall mention satisfactory results for the same:
Surface dry time
Hard dry time
Scratch Hardness
Viscosity
Opacity
Brush ability
Flash point
Volatile contents
Concrete panel test
Crack Filling Material and Glue Adhesives:
Crack filing material as well as glue adhesives shall be of approved make and as recommended by
manufacturer / Architect and approved by QA Department.
Consistency Test / Penetration test:
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After opening the can, a knife is introduced inside the paint and paint settings on knife are carefully
observed. No solid particles of paint should be observed. Also while introduced knife no cake formation
should be observed in the can. After stirring the paint a smooth uniform mix should be observed.
B) Other components (allied materials):
Primer:
Primer shall be of same make as that of paints / approved make as per the recommendations of the
paint manufacturer / Architect.
Thinner:
Thinner shall be of approved make and as per the recommendations of paint manufacturer / Architect.
Paint Brushes:
Brushes shall be of approved make with bristles in good condition.
Surface Finishing Rollers:
Surface Finishing Rollers shall be of approved make and be able to give necessary texture to finished
surface.
Other Materials:
Other materials such as glue, whiting powder, linseed oil, turpentine etc. shall be of good quality and of
approved make as per the recommendation of the paint manufacturer / Client / Architect.
Storage of Raw Materials:
Storing of Paints, Primers and Thinners:
1) Cans of Paint on receipt at site shall be sorted as per different manufacturers / as per their types.
2) Such sorted cans shall be stored on racks of height not more than 1.2 m and distance between racks
shall be kept as 0.8 m minimum. Cans shall be stored in such a way that Manufacturer’s name as well as
shade of the paint in the container is easily identifiable.
3) Primer and thinners shall also be sorted and stored near respective paint cans.
Storing of Paint Brushes:
1) Paint brushes shall be sorted as per their size and stored in the same room as that used for storing
paints. Plastic packing over brushes shall not be removed till their use.
2) At random checks, bristles of brushes shall be checked for their proper anchorage.
Other Materials:
1) Other materials such as bags of readymade putty, glue, whiting powder, linseed oil, turpentine, POP
etc. shall be stored in the same room as that used for storing paints. Care being taken so that these
materials do not come in contact with water.
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METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 136 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
Procedures for Internal Work:
Pre Painting Procedures:
1) Experienced painters shall be employed to carry out all painting works.
2) Colour code and shade card from Manufacturer of paint in reasonable numbers shall be made
available on site.
3) The paint in the drum shall be thoroughly mixed prior to application. The materials shall be mixed,
prepared and applied strictly in accordance with the instructions or recommendations of the
manufacturers.
4) It shall be ensured that all kind of civil as well as Electrical works are completed prior to start of
painting works.
5) Main door shall be provided with locking arrangement.
6) Maximum 30 days gap shall be provided between starting of painting work and completion of
plastering work.
7) Moisture content in the wall shall be particularly attended to. When sufficient time is not available for
the surface of walls to dry out, walls shall be applied with lime wash, colour wash, cement paint or oil
free distemper which will allow drying process to continue at reasonable rate through their films. In any
case glossy paint shall not be applied till drying process is complete.
8) No painting work shall be carried out in wet and very humid weather when there is danger of dew or
weather is otherwise unfavourable.
Surface Preparation:
1) After ensuring that wall surface is totally dry, it shall be brushed with emery paper (sand paper) to
remove dirt, loose dust and efflorescence, if any.
2) If any cracks are observed on wall surface the same shall be cut into a V shaped groove with a round
wheel cutter to the depth equal to thickness of crack and the groove shall be filled with POP or Crack
seal. It shall then be allowed to dry completely.
3) The entire plastered surface to be painted should be inspected for hollowness / voids, if any, and
necessary rectification should be done as per the guidance of QA Department.
During Painting Procedures:
1) Availability of all paints, primer, putty, thinner, glue, whiting powder, linseed oil, turpentine, brushes,
rollers etc shall be ensured prior to commencement of painting work.
2) The surfaces which are not to be painted shall be covered with empty cement bags or hessian cloth.
3) Paint to ceilings should be preferably done before paint to walls.
Primer:
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METHOD STATEMENTS
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PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 137 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
1) Only one coat of alkali resistant primer to applied (to be followed as per approved paint
Specification).
PVA Acrylic emulsion paint:
1) Entire process of application is same as that for Oil.
2) Only two coats of paint are applied. (As per approved paint specification / As a general guideline, 500
ml of thinner shall be added to 1 lit of Oil Paint from can or as per manufacturer’s guidelines to be
followed with slight variation in quantity of thinner to obtain paint of desired consistency).
NOTES:
Thinners (such as mineral turpentine) shall not be added to paints on the feeling that the consistency of
the paint supplied by the manufacture is too thick. If the paint has been manufactured to conform to the
specification, the paint shall have the correct consistency and shall not require further dilution. If there
is any doubt, the viscosity of the paint may be checked. If a slight adjustment of viscosity is necessary,
thinner, recommended by the manufacturer shall be used after prior approval.
PVA Acrylic Emulsion Paint:
1) Acrylic emulsion paint shall be prepared as per manufacturer’s instructions with slight alterations to
obtain paint of required consistency.
2) For an application of Acrylic emulsion paint, absolutely smooth surface of plaster is recommended.
3) Donga application is not required over gypsum.
Post Paint Procedures:
After application of final coat of paint satisfactorily, stains of paint shall be removed from doors and
door frames, tiling, skirting and hand railing, windows including glass panes, M S Grills, electrical switch
boxes etc.
Acceptance of Completed Work
Type of Check Acceptance
Brush / Roller marks Shall not be observed
Dust / Colour patches Shall not be observed
Damp spots Shall not be observed
Texture Uniform
Shade variation Shall not be observed
Glue adhesion test Satisfactory
Coat thickness Satisfactory
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Reference Documents :
ITP Reference No :
METHOD STATEMENT
FOR
EXTERNAL PAINTING WORK
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METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 139 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
SR. EFFECTIVE REV. MSS MANAGER MSS PROJECT CLIENT
CLIENT QA/QC
NO. DATE NO. QA/QC MANAGER SUPERVISOR
EXTERNAL PAINTING WORK
General
Paint is combination of resins, pigments, binders (natural or synthetic), additives and solvents.
Specifications
There are various types of paints depending upon the material, base etc. Accordingly the paint is
classified as mentioned below:
Material:
Cement paint
Acrylic paint
Textured paint
Base:
Water based paint
Oil based paint
Polymer based paint
Basic Properties of paint:
Durability
Breathability
Dust / dirt proof
Washable
Anti-fungal / algae
Water repulsive
U V Resistance
Raw Materials, their Inspection and Acceptance:
Paints
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Page 140 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
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CONTRACTOR
NAME:
1) Cement based paint / acrylic paint shall be appropriate make as per specifications of Architect.
2) Cement paints / acrylic paint which is delivered in HDP bags / drums shall be checked for following
details on the packings:
Manufacturer’s name
Batch and lot number
Date of manufacturing
Expiry date
ISI mark
Special instructions by manufacturer for proper mixing and application as also to maximize product
performance and minimize wastage.
ECO (Eco friendly) mark (if any), stating criteria for which ECO mark is obtained.
Percentage of toxic like Lead, Cadmium and Chromium (if present)
3) Colour code as well as colour shade shall be matched with that mentioned in the purchase order
before acceptance.
4) As a general guideline, this shall be done by mixing about 5 kg of cement paint with suitable amount
of water (Manufacturer’s literature shall be referred for this) to obtain paint of desired consistency and
then applying the paint in the form of vertical bands on already plastered exterior wall surface in 2 coats
with curing as specified later. Colour shade is then observed after 14 days, which should match with the
required shade, for the purpose of acceptance of paint.
5) Readymade acrylic paints are available in drum packing.
6) Paint Manufacturer’s literature should clearly mention that following tests have been carried out in
the laboratory and shall mention satisfactory results for the same:
Surface dry time
Hard dry time
Scratch Hardness
Brush ability
Concrete panel test
Crack Filling Material and Glue Adhesives:
Crack filing material as well as glue adhesives shall be of approved make and as recommended by
manufacturer / Architect and approved by QA Department.
Paint Brushes:
Brushes shall be of reputed manufacturer with bristles in good condition.
Procedures for External Painting Works (Cement & Acrylic):
Pre Painting Procedures:
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Page 141 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
1) Experienced painters shall be employed to carry out all painting works.
2) Colour code and shade card from Manufacturer of paint in reasonable numbers shall be made
available on site.
3) It shall be ensured that all kinds of Civil as well as Electrical works are completed prior to start of
painting works.
4) Minimum 30-60 days gap shall be provided between starting of painting work and completion of
plastering work based on type of paint to be used.
5) Single / double scaffolding shall be erected as per required height.
Surface Preparation
1) After ensuring that wall surface is totally dry, it shall be brushed with emery paper (sand paper) to
remove dirt, loose dust and efflorescence, if any.
2). Wire brush to be used for cleaning the surface for any algae / fungal developments if any. Water jet
can also be used or both for the same.
3) If any cracks are observed on wall surface the same shall be filled with Crack filling material and
allowed to dry completely and cured, if required as per manufacturer’s specifications.
4) Edges shall be particularly attended to and finished to line and level.
5) The entire plastered surface to be painted should be inspected for hollowness / voids, if any, and
necessary rectification should be done as per the guidance of QA Department.
During Painting Procedure:
1) Availability of all paints, glue and crack filling material shall be ensured prior to commencement of
painting work.
2) The surface shall be wetted at least 2 Hrs prior to painting for cement paint. For acrylic paint, wetting
of the surface is not necessary. However, manufacturer’s recommendations should be followed for the
same.
3) Paint shall be prepared as per manufacturer’s instructions.
4) When weather condition is very dry, the work shall be carried out ‘in the shadow’ by providing
curtains.
5) Paint in the buckets shall be continuously stirred to obtain uniform mixture and to prevent
segregation.
6) Waterproof polymer coat for dead walls is necessary to avoid leakages. However application of
primer coat is also necessary before polymer coat or as specified by manufacturer.
7) Anti-fungal / repellent coat for all walls except dead walls is necessary to avoid development of
algae / fungus on painted surface. This coat can be done with the help of spray machine.
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NAME:
8) 1st coat of paint shall then be applied. Application with brush shall be one stroke downwards, one
stroke upwards and one stroke from left to right.
8) After cement paint has hardened (i.e. 12 hrs. after application of cement paint) it shall be cured.
Curing shall be carried out by fogging (using a fog spray)/ sprinkling by water 2-3 times a day for 2 days.
9) For acrylic paint curing is not required. Here a gap of minimum 8 hour should be maintained between
two coats.
9) In hot, dry weather, 1st coat shall be moistened before application of 2nd coat. (For cement paint
only)
10) 2nd coat of paint is then applied just like 1st coat and cured in the same manner. Curing of 2nd coat
shall be carried out for at least 2 days. (Curing should be done for cement paint only whereas no curing
is required for acrylic as well as textured paint)
11) Painted surface can be protected from hot sun and wind by providing wet Hessian cloth barriers.
12) 3rd coat shall be applied, if specified in work order / by Architect. 3rd coat thickness shall be thinner
than the first two coats.
13) However entire painting work can be done by spray machine.
Post Painting Procedures:
After application of final coat of paint satisfactorily, stains of paint shall be removed from doors and
door frames, tiling, skirting and hand railing, windows including glass panes, M S Grills, electrical switch
boxes etc.
Textured Paint
Ruf –Tuf Texture:
Coat of Acrylic Quartz Granule coatings shall then be applied with trowel and then grooved with a
specially designer trowel according to the specified design. This coating would be approximately up to
2.5mm according to the wall condition. This application is recommended for preventing the dampers
and to be applied on exterior walls to give maximum integrity to the walls. It is washable – waterproof.
NOTES:
There are various other types of textured paint available which can be used as suggested by Architect /
Interior Designer.
Synthetic Resin Base Coat with Acrylic Overcoats (renova) in Plain / Stone / Metallic finish
(Procedures):
1) The surface shall be thoroughly cleaned off all dirt, dust, mortar dropping and other foreign matter,
before paint is to be applied.
2) Application of primer coat is necessary over the entire surface to be texture painted.
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3) Synthetic plaster reinforced by using fibre and based on a chemical which is superior type of cladding
material having acid and alkali resistant properties, can be applied to any hard based plain surface both
internally and externally. It does not require any further application or treatment once it is applied on
the surface. It is available ready-mixed for any desired colours which can be applied by a trowel. This will
avoid cracks formation as well as provide a waterproofing coating on the surface treated.
4) A cement plaster base is required which shall be roughened lightly with wire brush so as to form very
mild keys. The surface shall be well cured before the application of synthetic plaster.
5) Synthetic plaster then be applied in five coat i.e. one coat of plaster by trowel and subsequent four
coats of chemical overcoat by brush in approved colour and finish as specified (plain / stone or metallic).
Acceptance of Completed Work
Type of Check Acceptance
Brush / Roller marks Shall not be observed
Dust / Colour patches Shall not be observed
Damp spots Shall not be observed
Texture Uniform
Shade variation Shall not be observed
Glue adhesion test Satisfactory
Coat thickness Satisfactory
Records :
Reference Documents :
ITP Reference No :
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Page 144 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
METHOD STATEMENT FOR
TILING, SKIRTING, TOILET DADO &
KITCHEN PLATFORM WORK
SR. EFFECTIVE REV. MSS MANAGER MSS PROJECT CLIENT
CLIENT QA/QC
NO. DATE NO. QA/QC MANAGER SUPERVISOR
TILING, SKIRTING, TOILET DADO & KITCHEN PLATFORM WORK
Raw Materials
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NAME:
Cement:
1) Cement shall be OPC 43 Grade or PPC and not more than 8 weeks old. 53 Grade if used shall be
adequately blended with fly ash. PPC, PSC or OPC-Fly ash combination is recommended because of low
heat of hydration.
2) Cement shall be free from lumps.
Natural Sand:
For tiling works no detailed checking of sand is required. Sand for wall tiling should be 600 micron
passing.
Water:
Water for Tiling Works following checks are important on water used for curing to avoid efflorescence:
Sulphates: Not greater than 0.05 %
Chlorides: Not greater than 0.10 %
Admixture: Admixture like tile adhesives / liquid tile adhesives (can be used for better bonding) shall be
from reputed manufacturers. Care shall be taken to see that it is compatible with the Type / Brand of
cement being used.
Grouts, Adhesives, Colouring pigments, Spacers, Masking tape:
1) Grout used for sealing of gaps between tiles shall be of approved make and shall be stain resistant.
Adhesives shall be of approved make.
2) If specified, Colouring pigments matching with the shade of tiles shall be used.
3) Spacers and masking tape shall be as suggested by Architect.
Mortars for tile bedding:
Approved mix from Client / QA Department shall be used for mortar for tile bedding as well as wall tiles
Tiles:
Tiles shall be vitrified, Ceramic, Glazed or Porcelain of make and colour as specified on drawings in the
specification. Tiles, on receipt of every lot, shall be checked visually for any cracks, chipped surfaces,
colour variation and arrow mark. If tiles are not found satisfactory, then the entire lot of tiles shall be
rejected. However, following tests shall be carried out on tiles for every receipt of lot, for their
acceptance.
Testing frequency of tiles shall be after every 2000 tiles (considered as a lot) from the same
manufacturer for same colour / size / type or when the source of supply changes.
For testing purpose number of tiles selected shall be as per table. Tiles shall be selected at random and
subjected to following tests and acceptance criteria.
Failure of 2 or more tiles as per tolerance given in Table shall be liable for rejection of entire lot.
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If only 1 tile fails to satisfy criteria then retesting of tiles shall be carried out as earlier on fresh tiles.
No tile should fail in retesting considering tolerances.
Tests on tiles:
Dimensional Analysis for tiles:
A) Measurement of length and width:
10 tiles shall be chosen at random from a given lot.
Length and widths of all tiles shall be measured between end corners of tiles. (Leaving 5mm from
corners)
In all 40 readings shall be obtained.
Average of these 40 readings shall be compared with the ordered sizes of tiles.
B) Measurement of thickness:
10 tiles shall be chosen at random from a given lot.
Diagonals shall be drawn on all tiles. Thickness of tiles shall be measured at the centre of 4 segments
so formed with the help of micrometre.
Average thickness of all 40 readings shall be calculated and shall be compared with the specified
thickness of tile.
C) Measurement of straightness of sides:
10 tiles shall be chosen at random from a given lot.
For measurement of straightness of sides, a steel square shall be used. Deviation from straightness _
(delta) shall be measured as the difference of straightness between that at 5mm from corners of
tiles and that at centre of corresponding edge of tile.
D) Measurement of rectangularity
10 tiles shall be chosen at random from a given lot.
Tiles shall then be placed over a steel plate with studs at 5mm from corners.
Difference in size, _ of tile is checked at 5mm from corners for all four sides separately, by rotating
the tile.
Deviation of rectangularity for each side shall be: Δ *100 / L, where L is corresponding length of tile.
Field test:
About 2” high bed of sand shall be made on site and levelled. Tiles chosen for test shall be placed on
them touching each other so as to form sufficiently levelled top of tiles. Number of tiles to be chosen for
testing shall depend upon the size of tiles, for which following table is given.
SIZE OF TILES NO. OF TILES CHOSEN FOR TEST
350 mm x 350 mm 20
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152 mm x 152 mm x 5 mm 20
After placing the tiles on sand bed, diagonal length of the square so formed shall be measured and
diagonal length shall be match with the calculated diagonal length. No tolerance shall be allowed on
diagonal length measured.
E) Surface Flatness:
10 tiles shall be chosen at random from a given lot.
A flat calibrated plate of steel or glass 10mm thick with studs is used for determining a plane by
adjusting studs at three corners of tile (5mm away from corner)
1) Center of curvature:
∂ (Center of curvature) is the difference in level at the center of tile and the level of plane as determined
above
2) Edge of curvature:
∂ (Edge of curvature) is the difference in level at the center of edge of tile and the level of plane as
determined above.
3) Warpage of curvature:
∂ (Warpage) is the difference in level at the fourth corner of tile and the level of plane as determined
above.
F) Water Absorption Test for Ceramic / Glazed tiles:
5 tiles are chosen at random from a given lot (Area of each tile >400sq.cm), whereas 10 tiles shall be
chosen (Area of each tile <400 sq.cm).
Tiles having sides larger than 200 mm, shall be cut into pieces (Each having area <400 sq.cm), but all
tiles pieces, so formed shall be tested.
Tiles to be tested shall be oven dried and then cooled to room temperature and weight of each tile
m1 is noted.
Tiles are then kept immersed in distilled water, each tile separated from each other and kept
immersed in water in such a way so as to keep 50 mm water depth above and below the tiles.
Water in then heated till boiling temperature and tiles are kept immersed in boiling water for about
2 Hrs.
Tiles are then wiped dry with Chamois leather and placed in cold water for about 4 Hrs. and wt of
each tile m2 is noted.
Percentage of water absorption = (m2-m1)*100/m1 and shall not be greater than 10%.
NOTES:
Vitrified tiles are not soaked before fixing.
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G) Scratch test:
At least 3 tiles are chosen randomly from a given lot.
With the help of sharp nail 4 lines are drawn on each tile, by applying uniform pressure. No scratch
mark should be observed.
Reference shall be made to Table 1 for acceptance criteria of tiles.
TABLE 1: Guidelines for Inspection of Tiles
Sr. Description Mode of Inspection Acceptance Frequency
No. Criteria
1 Dimensional Field test: Every 2000 tiles
Analysis (10 tiles Length-Ceramic, Porcelain and glazed tiles. ±1 mm or source changes
from lot)
Width- Ceramic, Porcelain and glazed tiles ±1 mm
Thickness- Ceramic, Porcelain and glazed tiles ±0.5 mm
Length-Vitrified Tiles ±0.5 mm
Width- Vitrified Tiles ±0.5 mm
Thickness- Vitrified Tiles ±0.5 mm
2 Measurement of Field test No Every 2000 tiles
straightness (10 tiles deviation or source change
from lot)
3 Measurement of Field test No Every 2000 tiles
Rectangularity (10 deviation or source change
tiles from lot)
4 Surface flatness (10 External Lab test ±0.2 mm Every 2000 tiles
tiles from lot) or source change
5 Canter of curvature External Lab test ±0.2 mm Every 2000 tiles
(10 tiles from lot) or source change
6 Edge curvature (10 External Lab test ±0.2 mm Every 2000 tiles
tiles from lot) or source change
7 Warpage (10 tiles External Lab test ±0.2 mm Every 2000 tiles
from lot) or source change
8 Water absorption External Lab test <- 10% Every 2000 tiles
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5 tiles(area>400cm2) or source change
10
tiles(area<400cm2)
9 Scratch test (At least Field test No scratch Every 2000 tiles
3 tiles from lot) mark or source change
observed
on tiles.
NOTES: Above tolerances are recommended for achieving good workmanship at site. (IS/EN standards
being quite liberal)
Procedure for flooring and skirting works:
Flooring
A) Pre Tiling Procedures (Flooring):
1) Latest architectural drawing shall be made available on site indicating start point, joints, level, offset,
type, colour, size and laying pattern etc.
2) Conduiting works, if required, on a slab surface shall be completed. Nahani traps as well as washing
machine outlet pipe shall be provided as shown on the drawing.
3) Slab surface shall be cleaned by chipping if required, and wetted thoroughly. The naked slab shall be
treated with cement slurry with non-shrink material to avoid seepage of water below through shrinkage
cracks, if any.
4) Tile layout shall then be marked on the floor, with correct size of tiles, and clear-cut marking of
starting point for fixing of tiles shall be done. Tile edges being kept at right angles to plastered faces of
walls or as specified in drawing.
5) It shall be ensured that quality of tiles is satisfactory as per approved sample and proper sorting of
tiles should be done to have uniformity in size, colour and shade room wise.
6) Proper thiyya (level pads)s of tiles shall be taken at all four corners of rooms where tiles are to be
fixed and shown to the site in charge / site engineer before work begins. Floor level offset (1/2”
minimum or as specified on drawing) and slope shall be considered while taking thiyya (level pads)s for
toilets and terraces.
7) Floor thiyya (level pads)s shall be taken starting from stair landing and passage area first and then
within the rooms, keeping proper offsets (if any) as mentioned on drawing. Thiyya (level pads)s thus
taken for entire floor shall be checked by site engineer before tiling is started in any of the rooms.
8) Finished floor level so decided shall be clearly marked on each wall.
B) During Tiling Procedures (Flooring):
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FORMATE ID:
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DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 150 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
1) Tiles (Ceramic and Glazed) shall be soaked by completely immersing tiles in water for about 3 hours
and then drained for minimum period of 30minutes prior to their fixing in position.
2) Recommended mix proportion for mortar bedding should be used as per manufacturer’s specification
and/or approved by Q A Department.
3) If mortar bed thickness works out to be more than 2”, then the additional thickness shall be made of
by placing nominal screed concrete (PCC (1:3:6) mix or as specified by Client / QA Department) and it
shall be cured for at least 3 days and then fresh mortar shall be laid over it.
4) For laying of tiles alternatives below shall be followed:
Alternate 1:
Once mortar bed dries sufficiently cement slurry shall be laid (cement or Cement+ LTA (liquid tile
adhesive) as per manufacturer’s specification) over mortar bed and levelled using straight edge.
Tiles shall be laid simultaneously as cement slurry or Cement + LTA is spread along with Bonding
agent (if specified) and laying shall be done so that all joints of tiles match without showing any
offsets.
Alternate 2:
Mortar bed is cured for 3 to 7 days. Rich cement sand mortar (1:1) 4-5 mm thickness; using fine sand
shall be applied over cured mortar bed.
Tiles shall be laid simultaneously as rich cement sand mortar is applied and laying shall be done so
that all joints of tiles match without showing any offsets.
For tiles of size 900 x 900 and above; alternate 2 shall be adopted.
5) Use of arrow marks at the back of tile shall be made while fixing tiles. Straightness of joints shall be
maintained throughout. Tile fixing procedure shall be confirmed from the manufacturer, if required, or
under special circumstances. This is especially required when a particular design pattern is required on
the finished tile surface.
6) Each tile after placing shall be tamped with rubber mallet to form accurately levelled surface.
Hollowness beneath the tiles shall be checked from time to time by tamping and checking the sound
produced. Corners of tiles shall be specially attended to for checking hollowness beneath.
7) It is strongly recommended that all tile joints shall be maintained with the help of spacers (gap 1.5mm
and above) and filled with approved sealant of matching / contrast colour. However, architectural
drawings shall be followed.
8) Polyurethane foam of 5-6 mm thickness shall be provided along all four edges of room to cater for
expansion of tiles where spacers are not provided.
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MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
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9) Proper offsets as well as slope (1:100 recommended or as specified on drawing) shall be provided for
tiles in toilets as well as tiles in attached terraces. Offsets shall be provided using 40x40x3 aluminium
angles. As far as possible, threshold patti should be used.
10) Skirting tiles shall be fixed over floor tiles.
11) Antiskid tiles are recommended for stairs, toilets and attached terrace and joint free rectified tiles
are recommended in kitchen area for hygiene consideration. It is recommended that floor tiles of
swimming pool be fixed using LTA.
C) Post Tiling Procedures (Flooring)
1) Next day joints of tiles shall be raked little with thin metal sheet and filled with grout of matching
shade and cured for at least 3 days. Use of half round tool shall be made for filling joints, where spacers
are used.
2) After curing is over, joints of tiles shall be covered with masking tape to prevent entry of dirt into it
and shall be covered with a layer of POP with paper underneath, for protection against scratches due to
dragging of objects over them as also stains caused due to dropping of acids, detergents and other
heavy objects and footmarks.
3) Natural stone tiles shall be polished after a gap 15 days after fixing of tiles and polished surfaces shall
be well protected as above.
4) Staircase treads shall be checked for perfect line dori from topmost tread to bottommost tread.
Skirting:
1) Skirting work shall start after masking of joints in tiles is complete.
2) It is recommended that skirting face shall be flush with wall plaster face and groove above skirting
shall be avoided since dirt accumulates within the groove. However, architectural drawings shall be
followed.
3) Where Architect has particularly recommended skirting to fixed in offset with plaster, following
precaution shall be taken:
a) Wall plaster shall be completed in perfect plumb and line leaving a gap of height (50-100mm more
than skirting height, at bottom).
b) Temporary thiyya (level pads), using skirting tiles shall be taken from wall by fixing two skirting pieces,
one at each end of the wall and line dori shall be stretched across them.
c) Skirting tiles shall be fixed in plumb with the thiyya (level pads) so taken.
d) Gap above skirting shall be applied with plaster and trowelled flush with plaster above.
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e) This is to ensure uniform offset of skirting over plaster.
4) Skirting edges and floor tile edges shall perfectly match.
5) Skirting at offsets shall be matched at 45º to show a clean edge.
6) Skirting shall be fixed in such a way so as to keep its top level in perfect line and level of plaster.
Staircase
1) Tiles over staircase shall be anti-skid type unless specified otherwise by Architect.
2) If natural stones/natural stone tiles are used over steps, at least three grooves shall be made near
nosing.
Procedures for Wall Tiling for Kitchen and Toilet
a) Pre Tiling Procedures (Wall tiling/Dado)
1) Latest Architectural Drawing shall be made available on site.
2) Finished plaster surface shall be checked for right angles and diagonal shall be corrected for the same,
if not found satisfactory.
3) It shall be ensured that chases in masonry made for concealed piping are properly rendered with
application of chicken mesh, non-shrink mortar and cured. It must be ensured that electrical boxes are
fixed in position. All rendering works as well as minor repair works using mortar shall be cured using
curing compounds or as directed by Quality Department.
4) Wall tile thiyya (level pads)s shall be taken before fixing of plumbing pipe outlets and wall tiling layout
shall be clearly marked on the plastered surface with clear cut marking of starting point.
5) Nominal mix proportions for mortar tile fixing shall be decided by Quality Department.
6) Tiles (Ceramic and Glazed) shall be soaked by completely immersing tiles in water for about 3 Hrs. and
then drained for a minimum period of 30 minutes prior to their fixing.
7) If tiles are to be fixed up to ceiling thiyya (level pads), ceiling thiyya (level pads) shall be checked for
perfect horizontal thiyya (level pads) and necessary rectification shall be carried out to achieve the
same, if required.
8) The wall on which maximum plumbing work is done shall be chosen first for fixing of wall tiles.
9) Plastered wall surface shall be wetted thoroughly 12 hours prior to time chosen for fixing wall tiles.
b) During Tiling Procedures (Wall tiling / Dado)
1) It shall be ensured that quality of tiles checked from QA Department. Also proper sorting of tiles shall
be done to have uniformity in colour and shade. Starting point for each wall shall be followed strictly as
per drawing.
2) Ensure mix proportions from QA Department to form mortar of suitable consistency.
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3) Use of Liquid Tile Adhesive is recommended while making mortar.
4) Mortar, thus prepared, shall be used before initial setting time of cement or cement fly ash mix.
5) Use of neat cement paste for fixing tiles shall be avoided.
6) Circular holes of required size shall be made on tiles at appropriate positions as determined from
markings on wall. Holes shall be made from back of tiles with the help of cutter machine.
7) Mortar shall be applied to back of each tile (8-10 mm thk coat of mortar) before fixing in position and
then tamped with rubber mallet to remove hollowness behind. Thickness of compacted mortar bed shall
not exceed 8mm.
8) For dado works in toilets, walls shall be marked with tile fixing layout with correct sizes of tiles to be
fixed. Tiles shall be fixed from bottom second layer (full tile) to top leaving bottom most layer of tile.
Each tile shall be fixed in plumb with tile thiyya (level pads) piece using plumb bob. Also line dori shall be
stretched between two corner tile thiyya (level pads) pieces and all tiles shall be fixed in plumb with line
dori. Bottom most layer shall be laid after fixing floor tiles. Bottom most tiles shall be cut to correct slope
of floor laid, before fixing. Care shall be taken so that top edge of bottom most tiles thus fixed is
perfectly horizontal. It should be ensured that bottom support should be removed 2 hrs. after
completion of wall tiling work.
9) Fixing of wall tiles in other areas including passage (where no slope is given to floor) shall be done
after floor tiles are laid and sequence shall be from bottom to top.
10) Cement slurry shall be poured within the gap between tiles and plaster after every two courses of
tile laying. This is to ensure that there are no voids left behind the tiles fixed.
11) Cleaning of the tile surface should be done immediately after completion of laying of tiles.
12) For other precautions to be taken, refer section of floor tiles. For kitchen flooring, slope should be
provided towards Nahani trap and waterproofing should be completed to sunk portion of nahani trap
and after completion of curing period flooring should be laid. The other procedure of kitchen flooring is
same as regular flooring.
c) Post Tiling Procedures (Wall Tiling / Dado)
1) Next day joints of tiles shall be raked little with thin metal sheet and filled with grout of matching
shade and cured for at least 3 days.
2) It is recommended to keep one floor tile box (as spare) for each flat for initial maintenance / repair
before possession and for subsequent handing over of remaining tiles to occupant.
Finished Product Acceptance
OPENINGS FOR DOORS / WINDOWS
Type of Check Acceptance
Frame fixing In perfect line, level and plumb
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PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 154 of 864
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NAME:
Exposed edges of frames Properly rounded / chamfered
Rebates/holes in frames As specified on drawings
Joints in frame members Shall not be allowed unless length is excessive
Colour shade of gap filling As specified
Floor Tiling and Skirting
Type of Check Acceptance
Bends in tile surface Not accepted
Defects in uniformity of joints Not accepted
Level difference in joints Not accepted
Defects in straight line of joints Not accepted
Variation in tile sizes at wall ends Not accepted
Variation in right angle of skirting with floor tiles Not accepted
Variation in right angle at corners of skirting Not accepted
Variation in top level of skirting Not accepted
Defects in grooves at top of skirting Not accepted
Difference in floor level of individual room Not accepted
Floor tile joints not matching with skirting joints Not accepted
Offsets provided in floor levels of toilets and terraces As specified on drawing
Joint filling of floor tiles as well as skirting Satisfactory
Tiles sounding hollow Not accepted
Butt filling for skirting Satisfactory
Colour shade of gap filling As specified
WALL TILING FOR KITCHEN AND TOILET
Type of Check Acceptance
Bends in tile surface Not accepted
Variation in Joint Thickness Not accepted
Variation in plumb of finished wall tile surface Not accepted
Level difference at joints Not accepted
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TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 155 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
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Colour shade of gap filling As specified
Additional checks for Toilet dado
Undulations in the top level of tiles for dado in toilet Not accepted
Defects in straight line of joints Not accepted
Finishing of cut-outs Satisfactory
Variation in right angle of walls Not accepted
Quality of joint filling Satisfactory
KITCHEN PLATFORM
Type of Check Acceptance
Facia patti In perfect horizontal level
Platform top In perfect horizontal level unless specified otherwise by Architect
Exposed edges of platform Properly rounded / chamfered
Kitchen sink Bottom and surrounding portion packed with mortar
Colour shade of gap filling As specified
Inspection Record :
Reference Documents :
ITP Reference No :
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Page 156 of 864
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MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
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NAME:
METHOD STATEMENT FOR
ALUMINIUM DOORS & FRAMES AND
WINDOW FRAMES
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METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 157 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
SR. EFFECTIVE REV. MSS MANAGER MSS PROJECT CLIENT
CLIENT QA/QC
NO. DATE NO. QA/QC MANAGER SUPERVISOR
METHOD STATEMENT FOR ALUMINIUM DOORS & FRAMES AND WINDOWFRAMES
1.0 SCOPE OF WORK
The work covered by this specification consists of supplying and installing
Aluminium Doors, Windows, ventilators etc. (sliding or hinged type) or as per approved drawing.
In case of conflict between the clauses of this specification and those in the standard, this specification
shall govern. In case of conflict between design basis or job specification and those in these
specifications the former shall govern.
2.0 GENERAL
The basic design of aluminium Doors, Windows and Ventilators shall conform generally to SANS
(Specification for Aluminium Doors, Windows and Ventilators) & SANS (Specification for Aluminium
Windows for Industrial Buildings). The Aluminium alloy used in the manufacture of extruded sections of
approved make shall correspond to SANS and the hollow aluminium alloy sections shall correspond to
SANS. The aluminium alloy coupling sections used shall conform to SANS.
Aluminium sections shall be powder coated or anodized as per specified in drawings.
The dimensions, minimum thickness and wt. per meter run of the extruded sections shall correspond to
the related drawings and specifications given for the work.
The approximate size of the windows and ventilators are given in the drawings for guidance. Slight
modifications in the dimensions are permissible to suit the sizes of manufacturers.
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Minimum wt. of extruded Aluminium sections are as under or as specified in the drawing
A) Doors For fixed frame:- a) Side& top member 1.975 kg/m b) Lock rail 1.594 kg/m c) Bottom rail
3.495 kg/m Glazing clips (beading) 0.182 kg/m For shutter frame 1.202 kg/m
B) Window /Ventilator: a) For fixed frames 0.639 kg/m b) For shutter frame 0.636 kg/m c) Glazing
clips (beading) 0.165 kg/m d) Coupling bars 0.933 kg/m e) Member for fixing the frame 0.463 kg/m.
2.1 Raw Materials, Their Inspection and Acceptance Criteria
Aluminium Sections:
1) Aluminium section shall be of reputed make / manufacturer as specified. Technical brochure /
literature for the same shall be made available on site from manufacturer.
2) Size, thickness and weight of Aluminium sections shall be as specified and approved in the sample. It
shall be checked on site after delivery and properly recorded. Weights of sections shall fall within the
range of ±10%.
3) Anodizing / powder coating/ shall be carried out through reputed applicators and shall have approved
shade and satisfactory finish. The coating shall be uniform and without scratches.
4) Anodizing thickness shall be restricted to 15 to 20 microns whereas powder coating thickness shall be
restricted to 65 to 80 micron.
5) All sections, including that of frames shall be perfectly straight, without any bends, twists etc.
6) Aluminium section shall preferably be cut and drilled prior to anodizing / powder coating to avoid
causing burrs or disturbance to the coating during their cutting to required sizes.
7) Burrs, if any, shall be de-burred using de-burring tool. Proper record of cut section with coding system
shall be maintained on site for assembly later.
8) Protective masking tape shall be applied over Anodized / Powder coated aluminium sections to the
full depth.
9) Approved samples of coated aluminium sections shall be made available on site for comparing with
new incoming material for cross checking.
2.0 SHOP DRAWINGS
The contractor if so directed shall submit four sets of shop drawings covering items of
work of this specification. The drawing shall show all dimensions, details of construction and
installation relating to adjoining and related works where same requires cutting or close fitting
and shall show all the reinforcement, gauges of metal, nomenclature of the various standard
sections used, welding anchorages or holdfasts, positions of all fittings and fixtures. Various units
shall be properly marked and their correct position shall be indicated. The marks and directions so
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indicated shall be painted on the fabricated members to facilitate erection at site. The work of
fabrication shall be taken up only after the shop drawings are approved by the Owner.
3.0 FABRICATION
Frames shall be square and flat, the corners of the frame being fabricated to a true right angle. Both
the fixed and opening frames shall be constructed of sections which have been cut to length, mitred
and welded at the corners. Where hollow sections are used with welded joints, argon arc welding or
flash butt welding shall be employed. Subdividing bars of units shall be tenoned and riveted into the
frame.
For hinged doors, windows, ventilators etc., proper reinforcement shall be provided for the hinges
so as to prevent the sagging of the doors, windows etc. at a later stage. The material and design of
the hinges shall be got approved by the owner/consultant before use.
The frames for doors, windows, ventilators etc. shall show no wrap or inferior workmanship. The
frames shall be designed for glazing on the outside of the frames unless specified otherwise.
Ventilators consisting of an inner opening frame and an outer fixed frame, shall be made as separate
units.
The Doors, Windows, Ventilators etc. shall be provided with necessary glazing bars as per drawing.
Weather bars shall be fitted to coupling sections wherever required.
Holes for fixing and coupling sashes shall be provided in the web of outside frame sections and of
outer ventilator frame sections where these occur at the perimeter of the sash.
Holes for glazing clips shall also be provided, one hole being located in the web of the section or tee,
on each side of the pane.
4.0 DOORS
For Doors, the outer frame \and sections shall be of aluminium extruded sections conforming to
SANS. The door shall be provided with glazing / infill panel which shall be fixed by means of
triangular clips and gaskets of suitable material as approved by the owner / consultant. All fixtures
and fastenings including hinges, tower bolts, decorative type handles, safety locking arrangement
etc. of approved make shall be provided.
The doors shall be provided with floor spring boxes if specifically required by the owner / consultant.
Door panel shall be 12 mm thick prelaminated particle board phenol bonded as per drawing.
6.0 WINDOWS
The windows shall be made from extruded aluminium sections of approved make conforming to
SANS.
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6.1 SLIDING WINDOWS
The outer frame shall be suitable for 2 track / 3 track / 4 track sliding as per requirement with
standard sliding shutter frame with top, bottom and vertical interlock system as per specification
and drawing.
Each shutter shall be provided with 2 nos. specially designed nylon moulded guides at bottom and
top with weather strip of suitable material all round on each sliding shutter and other accessories
for preventing leakages.
Special approved locking arrangement and two sets of nylon roller with bearing of approved quality,
handles and other fixtures shall be provided in each shutter.
Each shutter shall be provided with sheet glass / other specified material with approved quality
packing material around glass, glazing clips etc. as per specification.
Necessary approved hardware fittings shall be provided and fitted.
6.2 OPENABLE WINDOWS
The outer frame shall be made up of ‘Z ‘sections with intermediate transom or mullion sections as
per specification.
Each shutter shall be provided with sheet glass / other specified material with approved quality
packing material around glass, glazing clips etc. as per specification.
Each shutter shall be provided with all necessary fixtures and fastenings including aluminium
fastener type handle, aluminium stays, hinges, locking arrangement etc. as per specification.
6.3 FIXED TYPE WINDOWS
For fixed type windows, the outer frame shall be of aluminium single side groove sections with
intermediate double side groove sections at specified intervals as per specification.
Each shutter shall be provided with sheet glass / other specified material with approved quality
packing material around glass, glazing clips etc. as per specification.
6.4 LOUVRED TYPE WINDOWS
For louvered type windows, the outer frame shall be of aluminium single side horizontal groove
sections with intermediate vertical members of horizontal double side groove sections at specified
intervals as per specification.
The louvers shall be of glass / other specified material and shall be fixed on with heavy type
aluminium channels of @ 10mm x 10mm of approved size having one end closed to rest louvered
glasses at required intervals.
7.0 VENTILATORS
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The ventilators shall be made from extruded aluminium sections conforming to BSI
7.1 TOP / BOTTOM HUNG VENTILATORS
Both Top hung / Bottom hung ventilators shall be hung on aluminium alloy hinges which shall be
either cast or fabricated out of extruded sections. The aluminium alloy for cast hinges shall conform
to A-5-M of SANS and for extruded section of hinge to SANS. Top hung ventilators shall be provided
with a 300mm long peg stay of cast aluminium to A-5-M of SANS or folded from NS4 Aluminium
sheet of SANS complete with cast aluminium peg and locking bracket. The stay shall be welded or
riveted on to the bottom inner ventilator frame section and shall lock into the locking bracket of
similar material welded to the bottom outer ventilator section.
Alternately top hung ventilators may be provided with a 30cm cam opener of aluminium alloy to A-
5M of SANS fixed to the ventilator. Both peg stay and cam opener shall be capable of holding the
ventilator open in three different positions.
Bottom hung ventilators shall be provided with a pair of aluminium alloy folding side arms to limit
the opening of the ventilator. The aluminium alloy arms shall be either cast in alloy A-5-M of SANS
or fabricated from aluminium alloy sheet conforming to NS4 of SANS. When ventilator is closed, the
side arms shall be invisible.
7.2 CENTRE HUNG VENTILATORS
Centre hung ventilators shall be mounted on a pair of cup pivots made out of aluminium alloy sheet
conforming to NS 4 of SANS and A-5-M of SANS or of material approved by owner / consultant. The
ventilator shall be so balanced that it shall be capable of remaining open in any desired position
under normal conditions. Spring catch, catch -plate, cord-eye etc shall also be provided for proper
functioning of the ventilator.
8.0 GLAZING
All glass used for the purpose of glazing shall be float glass, clear, ground, figured or wired sheet
glass of the best quality as directed, thickness of glass shall be 4 mm thick for windows and 5.5 mm
thick for doors and partition wall with corresponding weights as recommended in relevant IS
specifications. All glass shall be free from blisters and all other defects and shall be fixed to the
frames by means of glazing clips, and approved putty. The number of glazing clips shall be 4
minimum per panel. The glazing may be fixed also by means of aluminium extruded beading
screwed with countersunk screws to the frames if approved by the owner / consultant. The glazing
shall conform to SANS.
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 162 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
No glazing shall be considered complete until all stains have been removed from the surface of the
glass. If directed, the glass shall be cleaned with spirit or any other approved material to remove
stains.
9.0 HANDLING OF DOORS, WINDOWS AND VENTILATORS
Care shall be taken in unloading and stacking windows and ventilators at site. They shall be
examined for any damage that may have occurred in transit and shall then be stacked upright (on
their sills) on level ground, preferably on wooden battens and shall not come into direct contact
with dirt or ashes.
Care shall be taken in ensuring that aluminium frames are not allowed to get into direct contact
with wet cement and mortar. During the period of storage, aluminium should be protected from
loose cement and mortar by means of suitable covering such as tarpaulins.
The tarpaulin shall be hung loosely on temporary framing to permit circulation of air to prevent
condensation.
10.0 INSTALLATION
Frames shall be installed and fixed in masonry / concrete structures as shown in the drawings to
plumb and true line that operation is easy and smooth. Parts such as hinges shall be cleaned off the
construction waste and shall be cleaned and polished with petrol/ and other agents as specified by
the manufacturer. The main frame of Doors, Windows, Ventilators shall be fixed in masonry or
concrete sections with approved quality and size screws at about 300mm c/c after drilling the holes
using raw plugs as approved by owner/ consultant.
If any other fixing method is adopted, it shall be got approved by the owner / consultant before
commencement of work.
11.0 ANODIZING
All aluminium sections shall be anodized in natural matt finish with an anodic film thickness of 40
microns or as specified in drawing. The anodizing must be seated by keeping the anodized sections
in boiling de-ionised water for a period of one hour. The aluminium frame shall be cleaned and
polished with petrol or any other agents as specified by the manufacturer.
A thick layer of clear transparent lacquer based on methacrylates or cellulose butyrate, shall be
applied on aluminium doors, windows and ventilators by the suppliers to protect the surface from
wet cement during installation. This lacquer coating shall be removed after installation is completed.
12.0 POWDER COATED:
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PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
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NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
All aluminium section shall be powder coated of minimum 30 microns or as specified in
drawing or as per owner/ consultant.
Acceptance of Completed work
Type of Defect Acceptance
FRAME
Plumb and right angle In plumb
Fixing of screws By drilling holes and staggered, Spacing as
specified
Holes Satisfactory draining
Damage of frame after fixing Not accepted
Gaps between frame and plaster as also between Filled with silicon sealant of matching colour
different members
Window frame bottom Cleaned with air blower
DOORS
Door when slides Smooth operation and no rattling noise
Number of roller bearings As specified ( minimum two per shutter)
Damage to Doors Not accepted
Easy removal of doors from frame Not accepted
Shutters locking With minimum effort and no noise
Rubber gasket / wool pile / EPDM gasket Good quality and fixed at proper position
All doors As per drawing
When all shutters are fully closed and checked No leakage of air should be observed
with vacuum cleaner
Gaps between window frame and plaster Filled with approved silicon sealant of matching
colour / transparent colour
Shutters obstructing while opening Not acceptable
Cleaning of shutters done With air blower
Records :
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Reference Documents :
ITP Reference No :
METHOD STATEMENT
FOR
FALSE CEILING INSULATION
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TITLE:
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Page 165 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
SR. EFFECTIVE REV. MSS MANAGER MSS PROJECT CLIENT
CLIENT QA/QC
NO. DATE NO. QA/QC MANAGER SUPERVISOR
FALSE CEILING INSULATION
1. DESCRIPTION:
Aerolite is a pink, high quality, Glass wool thermal and acoustic ceiling insulation that is bonded with
an inert, thermosetting resin. The strong, resilient, flexible blankets are supplied in compression
packed rolls and are easy to cut and install.
2. APPLICATIONS:
Ceiling insulation in: -
Residential buildings
Retrofit in existing homes
Top up insulation
Non-residential buildings
Main & Substation Buildings
Relevant structures.
3. QUALITY MANAGEMENT SYSTEM ISOVER
Products are manufactured according to ISO 9001:2000.
4. REFERENCE DOCUMENT:
e. Tender Specifications
f. Drawings
g. Manufacture’s Specifications
h. Client preferred Standard Codes
5. TOOLS NEEDED FOR INSTALLATION:
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A wood saw, tape measure and a balancing plank (to prevent ceiling damage).
6. MATERIALS:
Glasswool: 50 MM Thermal & acoustic ceiling insulation.
7. HANDLING & STORAGE
Store product under cover and in dry conditions. Store flat. Handle with care, especially on the
Edges and corners, which can be damaged if subject to sharp or heavy impact. Do not apply
Excessive pressure, for example by standing or sitting on the product, as permanent damage may
Be caused.
8. FEATURES & BENEFITS
Lifelong energy savings.
Lightweight and easy to install.
Exceptional thermal and acoustic properties.
Safe application and use.
Maintenance free.
Long product life - will not readily age.
SABS mark (SABS 1381 part 1).
Compression packed to reduce volume and optimise transport and storage.
9. INSTALLATION INSTRUCTIONS
1. Measure the distance between the timber roof trusses.
2. Cut the Aerolite while still in the bag to the correct width to snugly fit the space between the
Roof trusses.
3. Roll out the Aerolite between the roof trusses on top of the ceiling.
4. It is advisable to lay the Aerolite underneath any wiring and to cut around any down lights to
prevent overheating of light fitting.
5. Wrap off- cuts around pipes to prevent them freezing in winter.
WARNING: Be careful not to step onto the ceiling board as you may damage the board or fall
Through the ceiling.
10. CLIENT/ARCHITECTURAL SPECIFICATION
Install (50) mm thick flexible non-combustible lightweight “Aerolite “insulation material
Between the roof trusses and over brandering/purlins in a completed roof and ceiling system.
Installation strictly in accordance with the manufacturer’s detail and
specification.
11. PHYSICAL PROPERTIES
Rval Thickness Length Width k-value Pack Volume NRC Value
(m2.K/W)
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(mm) (mm) (mm) (W/m.K)
1.14 50 10000 1200 0.040 0.150 0.80
Start/End 1.88
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75
Process 8000
Alternate 1200 0.040 0.189
Document 0.95
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2.50 100 steps 6000
steps 1200 0.040 0.265 1.00
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2.88 115 7000 1200 0.040 0.274 1.05
3.38 135 5000 1200 0.040 0.250 1.10
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1.14 50 4000 0.400 0.040 0.050 0.80
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Typical values for glasswool type 1; 10kg/m3 for 50mm and 11kg/m3 for thicknesses 75mm
and above.
Aerolite 50mm and 75mm can be installed as top-up in homes that already have insulation
but do not meet the stipulated minimum requirements for new buildings in SANS 10400-XA
12. ENVIRONMENTAL SUSTAINABILITY
ISOVER products are manufactured according to ISO 14001:2004.
Less material, less energy and less emissions
- Zero ozone depleting potential (ODP)
- Zero global warming potential (GWP)
13. FIRE PROPERTIES
Non-combustible - tested to SANS 10177-5
Class 1 fire index rating-SANS 10177 Part 3
Class A1, s1, do according to EN 13823
EUROCLASS A1 as per EN 13501-1
14. THERMAL PROPERTIES
Contributes to indoor comfort and contributes to lifelong savings by reducing heat loss/gain
due to its inherent thermal insulation properties.
15. ACOUSTIC PROPERTIES
Offers exceptional acoustic properties and enhances indoor environmental quality by
absorption of noise. Aerolite ceiling insulation reduces the sound transmission to and from a
room.
16. DURABILITY
- Odourless, inert and fully compatible with all standard building materials and components
- Will not promote corrosion of steel, copper or aluminium
- Will not sustain vermin
- Will not breed or promote fungi, mould or bacteria
- Non-hygroscopic
- Dust settlement will not hamper the product’s performance
8. Records :
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NAME:
9. Reference Documents :
10. ITP Reference No :
METHOD STATEMENT FOR
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TITLE:
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Page 169 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
ROOFING SHEETING / CLADDING
SR. EFFECTIVE REV. MSS MANAGER MSS PROJECT CLIENT
CLIENT QA/QC
NO. DATE NO. QA/QC MANAGER SUPERVISOR
ROOFING SHEETING / CLADDING
1. PURPOSE :
The purpose of this document is to state the requirements of material, workmanship and construction
procedure to be followed during the execution of metal sheet roofing and cladding works.
2. SCOPE OF WORK
The work described herein shall cover providing and installing metal sheet roofing and cladding
including translucent sheets and all accessories such as flashings, capping, gutters, trims, supporting
straps, brackets, foam fillers, sealants and the work shall be carried out in strict accordance with this
specification and applicable drawings. Contractor should along with the supplier of the product shall
prepare shop drawings for roofing, cladding, gutters etc. and shall take the approval of Consultants prior
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MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
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NAME:
to manufacturing and supply. Based on roof slope, the climatic conditions at site considering the
refinery atmosphere site nearing coastal area and the span of roof and slope of the truss / portal , The
sheet supplier / Contractor shall propose the type of profiled sheet , Base metal thickness of the sheet ;
yield strength of the sheet ; the Galvalume coating thickness and the pre-coated paint type & it’s primer
and final coats thickness, colour and retention parameters in case of Pre-coated Galvalume / Aluminium
sheets to be used and the proposal shall be justified through proper calculations.
3. TECHNICAL REQUIREMENTS
On site roll forming shall be done if the Owner/consultant requires single length of roof sheet from
ridge to the eaves for leak-proof roof. Leak-proof roof system with 10 years performance warranty shall
be provided.
MATERIAL
3.1.1 General
Material for sheets and accessories shall strictly conform to SANS/BIS/BS/ASTM/AS
Specifications as mentioned. Supplier shall furnish test certificates for verification of the
Same and shall make arrangements for inspection and marking of the materials at his works.
Erection shall not be started before approval of materials including all accessories.
Length shall be such that number of joints are minimum. Wherever specified, to avoid longitudinal
overlaps for larger span, sheets shall be of single length and shall be site formed. Guard film should be
provided with the sheets to avoid the scratches due to handling during transportation; the Guard film
shall be removed immediately after installation of the sheets.
3.1.2 Steel Sheets
Profiled steel substrate shall be cold roll formed conforming to SANS. Base metal thickness without any
coating shall be minimum 0.6 mm with minimum yield stress 550 Mpa (SANS / ASTM A446, Grade E) as
required by consultants / Owner. On top of base steel any one of the following coatings should be
used:-
Plain Galvalume
Plain Galvalume sheets shall conform to AZ 200 of AS 1397 or ASTM 792 or SANS with hot-dip metallic
coating of 55% Al and 45% Zn alloy having total coating mass of min. 200 gms/sqm on both sides.
Galvalume with colour coating
Galvalume sheets shall conform to AZ 200 of AS 1397 or ASTM 792 or SANS with hot-dip metallic coating
of 55% Al and 45% Zn alloy having total coating mass of min. 200 gms /sq m on both sides with an
additional exterior pre-coated paint coating of Super polyester paint / PVDF paint coated with
conversion coating, corrosion inhibitive primer, final coat of Super polyester paint /PVDF paint 20
microns of selected colour on both sides, conforming to SANS or AS 2728 Type 3-4. Colour should be as
per Owner / Consultants choice.
3.1.3 Aluminium Sheets
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Aluminium sheets shall conform to SANS and shall be of either troughed profiled type. Thickness shall
be as per design but not less than 0.91 mm for roof and 0.71 mm for side cladding. Surface of sheeting
shall have uniform reflective finish either plain mill or stucco embossed as per Owner / Consultants.
Surface shall be free of blemishes and have uniform gloss and brightness. Bare aluminium sheets / Pre-
coated Aluminium sheets shall be pre-painted by giving suitable paint system treatment as specified by
approved manufacturer.
3.1.4 Insulated Cladding Panels
Insulated roof / wall cladding panels shall comprise of profiled Pre coated Galvalume / Aluminium steel
exterior and interior sheets (the material of the sheet shall be as given above in clause 3.1.2 or clause
3.1.3 ) with rigid polyurethane foam (PUF) or expanded polystyrene (EPS) or resin bonded mineral
wool / glass wool / fibre glass roll as insulation. Density of rigid polyurethane foam shall be 35 Kg/m3
and thermal conductivity (K) shall be 0.018 Kcal /mh0C. Minimum thickness shall be 30 mm or as
specified. PUF shall conform to SANS. Density of expanded polystyrene shall be 18 Kg/m3 and K value
shall be 0.028 Kcal /mh0C. Minimum thickness shall be 50 mm or as specified. EPS shall conform to
SANS. Polyurethane/EPS outer and inner sheets shall form a composite sandwich product having high
compressive strength and wide spanning properties. If resin bonded mineral wool or glass wool or fibre
glass roll is used as insulating material then first internal sheet shall be fixed to the structure. Then sub-
girts shall be fixed at purlin locations. Girt size will depend upon the thickness of resin bonded mineral
wool / glass wool / fibre glass roll. External sheeting shall be fixed on the sub girts. Resin bonded
mineral wool / glass wool / fibre glass roll insulation shall conform to SANS and thickness shall be
minimum 50 mm having a density of 48 kg/m3 for resin bonded mineral wool of K value 0.036 kcal /
mh0C, a density of 24 kg/m3 for resin bonded glass wool of K value 0.031 Kcal /mh0C and a density of 24
kg/m3 for resin bonded fibre glass roll of K value 0.025 KCal/mh0C. These type of insulations shall be
fixed in the cavity between the two sheets.
3.1.5 Translucent Sheets
Translucent sheets shall be of polycarbonate panels of approved make as specified by Owner /
Consultants with a minimum thickness of 2 mm and formed to match the profile of the metal sheeting
panels. Translucent sheet shall have a light transmission factor of 55% to 80% and solar energy
transmission of 25%.
3.1.6 Accessories
Materials and coatings for ridge capping, barge capping, apron flashing, cover flashing, monitors,
expansion joints and gutters shall be manufactured out of same material as roofing / cladding sheets
material and shall be shaped to match sheet profile.
3.1.7 Fasteners
Concealed fixing clips shall be used for steep sloped roof or if specially required by Owner/consultant.
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Generally Steel sheets shall be fixed with Self drilling self-tapping screws with Cyclone plates (screws &
plates having coating of 45 micron thickness of Zinc tin alloy & screws electroplated by cold mechanical
plating method, mesh belt furnace heat treated) or stainless steel self-drilling self-tapping screws of
approved manufacturer with EPDM seals. If required Fasteners shall have a protective polymer coating
covering the entire fastener surface, the head as well as the shank, over zinc electroplating. Polymer
coated screws should be as per SANS or AS 3566 Class 3.
For self-drilling / self-tapping screws, high rpm (2000-2500 rpm) drivers with high amperage (47 amps)
shall be used to achieve the proper torque to secure fastening. Drill bits shall be cleared out after the
completion of drilling of sheets.
Aluminium sheets shall preferably be fixed with roof manufacturer’s requirement. Silicone sealant shall
be used for filling joints. Wind ties and bracings and special connections as per codal requirement of
SANS for coastal areas.
3.1.8 Roof Gravity Ventilators
Aluminium / Stainless steel Roof Gravity ventilators of approved make shall be fixed in position as shown
on drawings and manufacturer’s specifications. The number of ventilators shall depend on the area and
extraction details; height of installation surrounding sheet profile.
3.1.9 Wall Louvers
Louvers shall be of units having minimum size of 1.0 m x 1.0 m with adjustable or nonadjustable
blades. Paints and colour should match side walls or as specified by Owner / Consultants. Louvers shall
include structural support members, necessary jamb trim, sealant and fasteners.
The louvers design should be such that water should not penetrate.
a. HANDLING & STORAGE AT SITE
The materials specified herein above shall be handled and stored in the manner so as not to damage the
same. The material damaged in transit, storage and erection or otherwise shall not be used and paid
for. Such damages shall be borne by the Contractor. Sheets shall be stacked on the firm and levelled
ground on wooden battens according to the approved stacking methods and /or as per instructions of
the manufacturer. Sheeting or panels shall preferably be stored with a slight inclination in longitudinal
direction to allow water that may get into the stack to drip off. Sheets shall be stored under cover
particularly when they are to be stacked for a longer period.
b. INSTALLATION & FIXING
The work shall be completed to the satisfaction of Owner/Consultant as per the approved detail
drawings and as per the instructions of the manufacturer wherever necessary and shall be approved by
the Consultants / Owner.
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Sheets shall be lifted onto roof supports with ribs up. First sheet shall be fixed in position with the
female rib facing the starting edge. Female rib of the second sheet shall be lapped with the male rib of
the first sheet and shall be fixed with side lap fasteners before fastening the second sheet to supports.
Same procedure shall be followed for subsequent sheets. For side cladding same procedure shall be
followed. Minimum end lap shall be 150 mm for roof and 100 mm for side cladding. Side lap shall be
minimum 75 mm. For roof pitches below 70 end laps shall be sealed with approved silicone sealants.
Roof sheeting shall be fixed by crest fixing only. Side cladding shall be fixed preferably by crest fixing but
can be fixed by valley fixing also. In valley fixing fastener locations should be as close as possible to the
ribs. Side lap fasteners to be fixed at an interval of 350-450 mm to hold the side laps of sheets firmly in
place and to maintain a weather-proof joint. Holes must always be drilled and not punched. Extreme
care shall be taken to avoid over tightening of fasteners which will lead to deformation of sealing
washers, sheet damage and sometimes damage of the fastener threads. Fixing of flashings in masonry /
concrete wall shall be done by applying cold applied liquid three component polyester resin base flexible
UV resistant waterproofing system of approved make laid as per manufacturer specification.
Specific workmanship shall be employed while carrying out work at laps and expansion
Joints to ensure zero leakage.
All the sheets and accessories which are found to be cracked / bend after fixing shall be replaced by
new ones. The cracked sheet so removed shall be salvaged by the Contractor by cutting into smaller but
sound lengths whenever ordered.
4. Records :
5. Reference Documents :
6. ITP Reference No :
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NAME:
METHOD STATEMENT FOR
PLUMBING & DRAINAGE WORK
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NAME:
SR. EFFECTIVE REV. MSS MANAGER MSS PROJECT CLIENT
CLIENT QA/QC
NO. DATE NO. QA/QC MANAGER SUPERVISOR
PLUMBING AND DRAINAGE WORK
General
Plumbing Definition:
Plumbing is installed in a building not only for convenience & comfort but also for sanitation & health.
We would term the plumbing of a building to start from the water main, utilize the water in the entire
building and right up to the connecting the sewage to the municipal sewer.
General Terms
a) Static Pressure:
Pressure head in term used in fluid mechanics to represent the internal energy of a fluid due to the
pressure exerted on its container. It may also be called static pressure head or simply static head. The
static head of pump is the maximum height (pressure) it can deliver. The capacity of the pump can be
read from its Q-H curve (flow Vs. height)
b) Head in Fluid Dynamics:
In fluid dynamics, head is the difference in elevation between two points in a column of fluid, and the
resulting pressure of the fluid at the lower point.
c) Friction Loss:
Friction loss refers to that portion of pressure lost by resistance to flow exerted on fluids while moving
through a pipe, hose or other limited space.
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 176 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
d) Water hammer:
Water hammer is a very loud banging, knocking or hammering noise in the pipes that occurs when the
flow is suddenly turned off. It is caused by a pressure or shock wave that travels faster than the speed of
sound through the pipes, brought on by a sudden stop in the velocity of the water or a change in the
direction. It’s also been described as a rumbling, shaking vibration in the pipes.
e) Cavitation:
Cavitation is defined as the phenomenon of vapour bubbles of a flowing liquid in a region where the
pressure of the liquid falls below its vapour pressure.
f) Air Lock:
An air lock is gas trapped in a high point of a liquid – filled pipes system. The gas, being lighter than the
liquid, rises to the highest point and restricts the flow of liquid. In very tall systems, the gas can prevent
flow entirely. Flushing the system with high flow or pressure can help move the gas away from the
highest point, or a tap/air vent valve can be installed to permit the gas to be vented.
g) Air Vent Valves:
A valve that releases air from a pipeline automatically without loss of water or introduces air into a line
automatically if internal pressure becoMSS less than the atmospheric pressure, is known as an Air Vent
Valve.
h) Pressure Reducing Valve (PRV):
When water is supplied to the flats from the overhead tank, the pressure of water increases as we go
downwards due to weight of water column above it. Thus the pressure is maximum at the ground floor /
1st floor and minimum at the top floor. Even in a Hydro-pneumatic system where water is supplied
directly from pump to flats the pressure is higher on the lower floors of each zone. So, the pressures
reducing Valves (PRV) is required in high rise building after every 24mtrs (80 feet) to regulate the
pressure. PRV’s also helps in reducing the water consumption by about 30%.
Acceptance of raw materials
A) G I Pipes (Internal & External Plumbing):
G I pipes shall confirm to IS 1239 and shall bear ISI mark as well as manufacturer’s name on it.
All concealed G I pipes shall be of class C.
All exposed G I pipes shall be at least of class B.
All G I fittings shall bear ISI mark as well as manufacturer’s name on it (“R” mark is preferred)
Number of threads in G I fittings shall be minimum 11 per 1” length, pitch of threads shall be around
2.4 mm and depth of threads shall be 1.48 mm.
Waste coupling for Wash Basin shall be half threaded with a slot for draining out overflowing water.
Waste coupling for Sink shall be full threaded.
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 177 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
NOTES:
All G I pipes and fittings shall be of the diameter and size as specified on the drawing. Class of all G I
pipes shall be checked by comparing their weights as per table attached (Table 1). Colour marked on
pipes shall not be followed blindly. Wall thickness of pipes shall also be checked.
B) C I Pipes (Internal & External Drainage):
C I pipes shall be heavy duty, painted black at the time of delivery and shall be free from any cracks
and blow holes. Internal wall surface shall be smooth.
Tests on CI pipes shall be carried out by checking their weights and wall thickness as per literature
provided by the manufacturer.
All other CI pipe fittings like Collar clamps, U clamps, Single Y, Double Y, Elbows and bends shall also
be checked in a similar way. They shall be checked for proper fitting into/over the pipes.
NOTES:
All C I pipes and fittings shall be of the diameter and size as specified on the drawing or as specified by
Architect.
It is desirable always to have provisions of door type fitting at each bend (in a drainage line) and for line
laid horizontally provision of cleanouts are kept before the branch connections, bends and at specific
intervals of 6
mtrs.
C) PVC Pipes (Internal & External Plumbing and Drainage):
Concealed PVC pipes shall withstand a pressure of 6 Kg/cm² and exposed PVC pipes shall withstand a
pressure of 4 Kg/cm²
NOTES:
All PVC pipes and fittings shall be of the diameter and size as specified on the drawing or as specified by
Architect.
It is desirable always to have provisions of door type fitting at each bend (in a drainage line) and for line
laid horizontally provision of cleanouts are kept before the branch connections, bends and at specific
intervals of 6 mtrs.
D) CPVC Pipes (Internal & External Plumbing):
CPVC pipes shall be visually inspected for any cracks or defects. Plastic clamps from the same
manufacturer should be preferred as far as possible. Metal clamps for CPVC pipes should be avoided.
NOTES:
All CPVC pipes and fittings shall be of the diameter and size specified on the drawing or as specified by
Architect.
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 178 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
For all pipes other than G I, manufacturer’s test certificate for following tests for pipes shall be obtained
and properly filed in at site, for easy reference:
Hot water pressure test
Pigment dispersion & physical dimension test
Reversion test
Impact test
Melt flow index test
E) PPR Pipes (Internal Plumbing):
All PPR pipes received on site shall be free from cracks and other defects. PPR Fittings, Bends, Elbows
shall be of approved make and pressure class PN 20/PN25
F) Concrete Pipes (External Drainage):
1) RCC Hume pipes of class NP2 shall be used for normal use and Hume pipes of class NP3 shall be used
for road crossings with vehicular traffic.
2) Concrete pipes shall be beveled end type or spigot and socket type, provided with collars as per
specification or as indicated on drawing. If collars are provided, it shall be ensured that pipes are
delivered with appropriate numbers of collars. Pipes delivered without collars shall not be accepted.
3) Pipes showing cracks and which are damaged during transport shall be rejected.
4) Joint line on pipes shall be as thin as possible.
G) STONE WARE GLAZED Pipes (External Drainage):
SWG pipes shall be checked for any cracks or defects before acceptance.
H) Gully Traps (External Drainage);
1) Gully traps shall be of size 150 x 150 or as specified.
2) On receipt at site, they shall be filled with water completely and kept overnight for checking leakages,
if any. Faulty Gully traps shall be discarded and not used anywhere.
I) Inspection Chamber Covers (External Drainage):
Inspection chamber covers shall be of Concrete or C I (Heavy duty/Medium duty/Light duty) and
dimensions as specified on drawings or as specified by Architect.
J) BRICKS (External Drainage)
The quality of bricks should be as mentioned in Masonry Method Statement.
K) Other Fixtures
(Internal Plumbing):
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 179 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
Other fixtures like Nahani Traps, WC Traps, Bottle Traps, EWC, wash Basins, Sinks, Anti Siphon pipes,
other WC fittings etc. shall be checked for any cracks, defects etc. Their size, shape and make shall be as
shown on the drawings or as mentioned in the specifications.
(External Plumbing):
Other fixtures like Pressure reducing valves, Gate valves, Foot valves, G I spouts, Clamps for pipes
etc shall be checked for any cracks.
Their size, shape and make shall be as shown on the drawings or as specified by Architect.
L) Sealants:
All sealants shall be of approved make.
Teflon tape shall be used as a thread sealant for GI / CPVC pipes.
Lead / Drip seal shall be used for jointing of CI pipes or otherwise specified by Architect.
“Habak”, “Tag”. “Hold tight” shall be of approved make.
For jointing of CPVC pipes and fittings, one step / two step solvent cement with primer as
recommended by the CPVC pipe manufacturer / as specified by Architect shall be followed.
Class Identification for GI Pipes (Table: 1)
SIZE Diameter of Pipes
In mm 15 20 20 32 40 50 65 80 100 125 150
In Inch ½” ¾” 1” 1 ¼” 1 ½” 2” 2 ½” 3” 4” 5” 6”
TYPE Wall thickness of G.I. Pipes in mm
Light Class 2 2.35 2.65 2.65 2.90 2.90 3.25 3.25 3.65 -- --
Medium Class 2.65 2.65 3.25 3.25 3.25 3.65 3.65 4.05 4.50 4.85 4.85
Heavy Class 3.25 3.25 4.05 4.05 4.05 4.05 4.05 4.85 4.85 5.4 5.4
TYPE Weight of G.I. Pipes ( kg / metre length)
Light Class L
mark ( Yellow 1.01 1.18 2.10 2.72 3.40 4.32 6.10 7.20 10.48 -- --
Mark )
Medium Class
M mark ( Blue 1.28 1.65 2.54 3.27 3.76 5.31 6.81 8.85 12.68 17.04 20.20
Mark )
Heavy Class H
mark ( Red 1.51 1.97 3.08 3.97 4.58 6.38 8.20 10.51 14.97 18.64 22.2
Mark )
The whole system is classified into following:
Internal plumbing & internal drainage
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 180 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
External plumbing
External drainage
Procedures
A) Internal Plumbing and Internal Drainage:
Pre Installation Procedures (internal plumbing / internal drainage works):
1) A licensed plumber shall be employed to carry out all plumbing works and a Photo Copy of his license
shall be kept ready for producing before any authorized agency coming for inspection.
2) It shall be ensured that base coat of toilet water-proofing is complete before staring any of the
following procedure.
3) It is necessary to have ledge walls for RCC shear walls for concealed plumbing network and the base
coat waterproofing should be necessarily done before laying of ledge walls.
4) Toilet walls shall be clearly marked with proposed tile locations (using nylon string dipped in white
colour solution) showing tile joints, routing pipelines over walls, locations of fittings and proposed outlet
of pipes. (Concerned architectural drawing showing exact distances from walls and finished floor level
(FFL) of toilet, shall be referred to while doing so and the drawing shall be kept ready for inspection).
Slight adjustments in pipe routing, if required, shall be made on site with consent of Site In charge for
keeping outlets of pipes at joints.
5) Finished tile plane shall be clearly marked on walls by fixing tile pads at four corners of walls.
6) Dado tile piece, if required, shall be kept at corner or at a place which is not easily detected.
7) Similarly, toilet floor shall be marked with correct position of sanitary-ware including bath tub fittings
and piping.
8) Flush tanks / Boiler or heater / Wash basin positions shall be marked on the walls.
9) Drainage outlet holes shall be clearly marked on walls, hole size being same diameter as that of outlet
pipe. Holes shall not be made in cast RCC members. Sleeves shall be planned and kept at the desired
location at the time of cast.
10) Ablution tap position shall be kept on right hand side unless specified otherwise on drawing.
During Installation Procedures (internal plumbing / internal drainage works):
1) Chasing of Brick-work shall start only after marking on Walls / Floors is approved.
2) It shall be ensured that all pipes / fittings / sanitary-ware / sealants etc. are as per approved brand /
as specified by Architect.
3) Sufficient lighting arrangement shall be provided for working in dark areas.
4) Chasing in masonry shall be done with the help of cutter machine and depth of groove in walls shall
be 15mm more than diameter of pipe to accommodate mortar and plane of cutting shall be parallel to
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 181 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
routing of pipeline. Within the chased portion light hammering shall be allowed, if it doesn’t cause harm
to masonry.
Installation of G I Pipes:
1) G I Pipes shall be cut to the required length as per layout on walls / floors and coconut oil shall be
used while threading.
2) Pipes shall be cut at perfect right angles and burrs, if any, shall be removed by debarring tool.
3) Number of threads in G I Pipes shall be minimum 11 per 1” length, Pitch of threads shall be around
2.4mm and depth of threads shall be 1.48mm.
4) Teflon tape shall be used as a sealant over threads while jointing pipes.
5) Concealed G I pipes including fittings shall be applied 2 coats of bituminous paint (Black Japan) before
installation. Asbestos rope OR alternative shall be tied around hot water pipes and Hessian cloth shall be
tied around cold water pipes. Over this, a coat of bituminous paint shall be applied for better protection
against corrosion.
NOTES:
For heat insulation it is recommended preferably to use poly – urethane pipe sleeves or use 2-3 mm
thick heatlon sheets. However the instructions given by Plumbing Consultant / Architect should be
followed
6) All G I fittings shall be washed with kerosene to remove rust inside, prior to their installation. Fittings
shall be fitted using “Habak” and “Teflon” tapes only.
7) The pipe assembly shall then be placed in chases.
8) Horizontal pipelines shall be laid perfectly horizontal and vertical pipelines shall be laid perfectly
vertical. Slant piping shall be avoided.
9) To keep G I lines in position 40 mm plumbing nails at 9” c/c on alternate sides of G I pipes shall be
driven in masonry.
10) Flushing lines shall be of minimum dia 1 1/4” and shall be separated from fresh water lines entirely.
All pipelines through which gravity flow is expected shall be laid with a minimum slope 1:100 or
specified on drawing.
11) All outlets shall be maintained at right angles and fitted with G I plugs. G I plugs shall project at least
½” beyond the face of plaster for fixing of fittings.
12) Open G I pipes shall be applied with oil paint as an anti corrosive treatment over a base coat of red
oxide primer.
13) Whenever pipes are embedded, insertion depth shall be marked on pipes.
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 182 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
14) All the open pipes shall be properly plugged in to prevent entry of mortar in pipes and also for
carrying out Pressure Test.
15) Control valves shall be provided for each toilet unit and valve position shall be easily accessible for
operating through toilet window, if possible.
16) Fittings for mixer unit in toilet shall be installed carefully so as to avoid mixing of hot water and cold
water.
17) Mouths of traps shall be plugged with suitable cloth to prevent entry of dirt and mortar into it.
Post Installation Procedures (internal plumbing / internal drainage works):
1) After complete erection of pipeline and plugging open ends, flushing of entire pipeline shall be carried
out by keeping only one of the pipe fitting open. Pressure test shall then be carried out using pump and
calibrated Pressure Gauge for minimum pressure of 10 Kg/cm² (or 1 ½ tiMSS the design pressure,
whichever is greater) by fully charging the entire section and keeping it pressurized for a period of at
least 30 minutes. During this period no leakage should be observed and pressure drop should not be
more than 0.3 bars
2) If leakages are observed during Pressure Test, necessary repairs shall be carried out and Pressure Test
shall be carried out again.
3) After the pressure test is successfully carried out, chases as well as holes shall be filled with non shrink
grout and the grout shall be cured for at least 3 days.
Note: in case, pipes other than G I are used, technical literature and Manufacturer’s user Guide Manual
shall be made available on site.
Installation of CPVC pipes:
Manufacturer’s Installation Instructions shall be referred to during installation of CPVC pipes. However
for general guidelines, refer to special requirements.
Special Requirements:
1) Pipes shall be cut to the required length using sharp edges cutter to have a square cut exactly
perpendicular to the pipe which provides maximum bonding area for the joint.
2) If cracks are observed during cutting, then the pipe shall be cut 50 mm beyond the crack and such cut
piece of pipe shall not be used anywhere.
3) Chamfering tool, file or pocketknife shall be used to give slight bevel at the cut end for easy entry of
pipe into the fittings. Burrs, if any, shall be removed with the help of debarring tool.
4) Pipes shall be wiped clean and made dry before installation of fittings.
5) PVC pipes should be embedded with proper encasing for internal drain to prevent damages, cracks
etc.
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 183 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
Application of two step solvent cement for jointing:
1) Application of Solvent Cement shall be done in well-ventilated area.
2) The exact position of fitting shall be marked on the pipe surface as well as on fitting surface.
3) Primer recommended by pipe manufacturer shall be applied to outside of pipe and inside of fitting.
4) After the pipe surface becoMCS tacky, a thin even coat of solvent cement shall be applied to inner
face of fitting and a thicker even coat shall be applied to outside face of pipes. Solvent Cement shall be
as recommended by the manufacturer of pipes.
5) Immediately after application of Solvent cement (i.e. Solvent Cement is still wet), pipe shall be
inserted in the fitting by rotating ¼ to ½ turn while pushing, to ensure even distribution of cement within
the joint.
6) Fitting shall then be held in correct position for about 10 seconds, till an even bead of Solvent Cement
is visible around the joint. If the bead is not continuous, it indicates that adequate Solvent Cement was
not applied.
7) Solvent cure time is 1 Hr for 1/2” to 1” dia pipes and 2 Hrs for 1 ¼” to 2” dia pipes or as recommended
by manufacturer.
8) Adequate safety measures shall be taken as per pipe manufacturer’s recommendation, while applying
solvent cement.
9) After assembly the pipe section shall be placed in masonry chases at correct positions and clamped
with plastic clamps (supplied by the pipe manufacturer) at 900 mm c/c for pipe dia less than 1” and 1200
mm c/c for larger pipe dia.
10) Masonry surface shall be smooth and without sharp edges around the pipes.
11) The entire pipe system is then Pressure Tested by first blowing out all air within and then filling it
with water completely. Applied Pressure and time for testing shall be as per recommendation of the
CPVC pipe manufacturer. During Pressure Testing no leakages should observed. If leakages are
observed, concerned pipe sections shall be replaced with new ones.
For application of one step solvent cement primer application is not required.
PPR Pipes:
For PPR pipes general guidelines given for CPVC pipes shall be followed. Polyfusion Welding Device with
Mortice shall be used for welding of PPR pipes and Teflon Tape shall be used as a sealant for threads.
Heating, Welding and Cooling time shall be as recommended by the manufacturer.
Fixing of Nahani Trap:
1) Nahani Trap shall be fixed along with water-proofing works.
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 184 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
2) Top level of Nahani trap should match with finish coat of water-proofing i.e. bottom level of flooring
above.
3) Nahani Trap shall be fixed with minimum 15 cm from side walls.
Fixing of Wash Basin and Sink:
1) Top level of Wash Basin shall be checked w.r.t. FFL as per Architectural Drawing
2) Waste coupling for Wash Basin shall be half threaded with a slot for draining out overflowing water
and waste coupling for sink shall be full threaded.
3) All Wash Basins and Sinks shall be provided with bottle traps before connecting to drain pipes.
Anti siphon pipe:
All WC fittings shall be connected to external Anti siphon pipe.
Joinery:
1) WC Trap connector:
a) PVC pipe shall be used as WC Trap connector
b) Lip ring with rubber lubricant shall be fitted over spigot portion of ceramic trap.
c) Over lip ring, PVC pipe connector which acts as socket shall be fitted.
2) PVC to PVC joint:
a) PVC pipe shall be cut with the help of toothed saw
b) 1/3rd thickness of pipe (spigot) shall be given a chamfer at 15º using coarse file.
c) Both spigot and socket shall be cleaned thoroughly.
d) Marking shall be made on spigot up to which joinery is required.
e) Joining lubricant shall be applied on spigot from marking to chamfered end and a rubber ring shall be
fixed over it, without twisting.
f) Spigot is then inserted into socket to 10mm less than the marking to allow for thermal expansion.
3) PVC to CI joint:
a) Inside face of PVC plug tee socket shall be roughened with emery paper and a thin coat of solvent
cement shall be applied over it with the help of brush.
b) Medium size sand is then sprinkled over it and allowed to dry for 5 minutes which will provide a
better bonding surface.
c) Gap between Nahani Trap and PVC plug tee shall then be filled with cement.
4) CI to CI:
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
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METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 185 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
For CI to CI connections, lead joints / drip seal joints should be used or as specified in drawing. Smoke
test shall be done after all the joints are filled & the branches brought up to ground level.
1) In C.I. pipes with lead joints the joints shall be first caulked with strands of spun yarn. The requisite
quantity of lead shall be poured / caulked into the joint & then shall be compacted by means of special
tools having chamfered edges & angled length.
2) In drip seal joint, two component epoxy based chemical is used instead of lead.
B) External Plumbing
Pre Installation Procedures:
1) A licensed plumber shall be employed to carry out all plumbing works and a Photo Copy of his license
shall be kept ready for producing before any authorized agency coming for inspection.
2) Approved plumbing drawing shall be made available on site.
3) For CPVC pipes, technical literature and manufacturer’s user guide manual shall be made available on
site 4) Layout of pipes shall be marked on external wall surface as also on terrace and shall get approved
from plumbing consultant. It shall be ensured that vertical lines so drawn are in plumb.
5) Holes shall be made in parapet wall. Diameter of holes shall be 1” more than the respective diameter
of pipes.
6) In Over Head Water Tank and Under Ground Water Tank GI pipe sockets shall be provide as inserts at
the inlet / outlet locations to avoid puncturing of RCC walls later.
During Installation Procedures (External plumbing):
Installation of GI Pipes:
1) GI pipes shall be cut to the required length as per layout on walls and terrace. Coconut oil shall be
used while threading.
2) Pipes shall be cut at perfect right angles and burrs, if any, shall be removed by deburring tool. Round
wheel cutter OR cutter recommended by manufacturer shall be used for cutting CPVC pipes.
3) Number of threads in GI pipes shall be minimum 11 per 1” length, Pitch of threads shall be around
2.4mm and depth of threads shall be 1.48mm.
4) All GI fittings shall be washed with kerosene to remove rust inside, prior to their installation.
5) Fittings shall be fitted using “Habak” and “Teflon” tape only while jointing pipes.
Vertical pipes shall be laid truly vertical by checking their plumb. Horizontal pipelines shall be truly
horizontal. Slant piping shall be avoided.
6) Adequate distance shall be maintained between main pumping lines and wall surface for
maintenance purpose.
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
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METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 186 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
7) Vertical pumping mains shall be double clamped near joints, connections, bends and turns to avoid
bursting of pipes.
8) Clamps for CPVC pipelines shall be of plastic or PVC as specified by manufacturer. (Metal clamps shall
be avoided). Clamps for vertical CPVC pipelines shall be kept loose for free movement of pipes near
expansion loop, if specified. Expansion loop shall be adequately supported.
9) Entry of pipes through walls shall be at right angles.
10) Pressure reducing valves shall be provided for high rise buildings and Control valves shall be
provided for each branch line of OHWT. Control valve position shall be easily accessible for operating
through toilet window, if possible.
11) Foot valve location shall be kept 4” - 6” above tank bottom / sump level. Non return valves shall be
provided near pumps.
12) Vent pipes shall be provided for all outlets through OHWT to prevent air locks.
13) Cleanout provision at bottom shall be provided for each line separately.
14) Pipeline on terrace shall necessary run along parapet and be properly anchored to parapet wall with
the help of saddles / clamps.
15) Underground main GI pipeline including fittings shall be applied 2 coats of bituminous paint (Black
Japan) before installation and shall be preferably supported on concrete pedestals.
16) In case internal piping network is to be connected to outside water supply lines of different material,
suitable adapters with sealants shall be used. Refer joinery at the end of this section.
17) Open GI pipes shall be applied with oil paint as an anti-corrosive treatment over a base coat of red
oxide primer.
18) Exterior grade latex paint shall be applied on CPVC pipes for UV resistance.
19) In case, solar water heating system is provided, temperature control system shall be installed and
adequate precaution shall be taken to avoid mixing of hot and cold water. Also GI hot water pipes shall
be wrapped with wool piles and Aluminum foil for which minimum 1” clear distance between wall and
pipe surface shall be kept.
Post Installation Procedures:
1) After complete erection of pipeline and plugging open ends, flushing of entire pipeline shall be carried
out by keeping only one of the pipe fitting open.
2) Gravity pressure testing shall then be carried out by completely filling the entire pipeline with water
for 24 hrs and leakages through pipelines, if any, shall be observed.
3) If leakages are observed during Pressure test, necessary repairs shall be carried out which may involve
replacing part of pipeline. Pressure testing shall then be carried out again.
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 187 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
4) After the pressure test is successfully carried out, holes in masonry shall be filled with non-shrink
grout and the grout shall be cured for at least 3 days.
Installation of CPVC pipes, application of two step solvent cement & joinery:
Same as mentioned in internal plumbing & internal drainage.
Checks and precautions on UGWT:
1) Injection grouting and box type waterproofing shall be done.
2) Waterproof plaster shall be applied to sides and bottom of tank from inside. Care shall be taken to
provide chamfers at the junction of side walls and bottom slab. Waterproofing slope shall be provided
towards sump.
3) Waterproofing of top slab shall also be carried out.
4) Other check points shall be
i) Provision of sump for fixing submersible pump as well as for collecting water and cleaning.
ii) Position of inlets and outlets as per drawing.
iii) Provision of adequate no of manholes.
iv) Sizes of manholes are proper and covers are in properly openable condition.
v) Provision of rungs as monkey ladder near manholes for large tanks.
vi) Inlet and Outlet pipes should be positioned and fixed with reinforcement before concreting.
Checks and precautions on OHWT:
1) Internal waterproofing of tank shall be carried out in the same way as described for UGWT.
2) Slope of internal base water proofing shall be towards outlet pipes.
3) Other check points shall be
i) Provision of compartment wall for drinking water, flushing water and fire water and separate outlet
for each.
Control valve for each outlet near the tank.
ii) Separate colour for above outlet pipes.
iii) Provision of ball valve and automatic water level indicator.
iv) Provision of overflow pipe which shall be connected to top terrace down take pipe.
v) Provision of wash out pipe.
vi) Provision of access to top with peripheral walkway with hand railing.
vii) Sizes of manholes are proper and covers are in properly openable condition.
viii) Provision of rungs as monkey ladder near manholes for large tanks.
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 188 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
C) EXTERNAL DRAINAGE
Pre Installation Procedures (External drainage works):
1) A licensed plumber shall be employed to carry out all plumbing works and a Photo Copy/Xerox copy
of his license shall be kept ready for producing before any authorized agency coming for inspection.
2) Approved plumbing drawing showing routing pipeline, location of Inspection Chambers and all
necessary Invert levels shall be made available on site.
3) Layout of sewage and sullage shall be marked on external wall surface and shall get approved from
plumbing consultant. It shall be ensured that vertical lines so drawn are in plumb.
4) Sleeves shall be kept in toilet / bath-room walls or holes shall be drilled in walls for connection to
sewage and sullage lines. Diameter of sleeves / holes shall be 1” more than the respective diameter of
outlet pipes. (Drilling of holes in RCC structure is not permitted).
5) In Septic tank, PVC pipe sleeves shall be provided as inserts at the inlet / outlet locations to avoid
puncturing of RCC walls later.
During Installation Procedures (External drainage works):
Sewage and Sullage:
1) All Sewage as well as Sullage lines shall be of Heavy duty CI or PVC and connections to them shall be
by plug fittings.
2) Where municipal drainage lines are not provided, sewage lines and Sullage lines are kept separate.
Sewage lines shall first be connected to septic tank and then further to soak pit whereas sullage lines
shall directly be connected to soak pits. (Reference shall be made to approved drainage drawings).
3) Where municipal drainage lines are provided, both Sewage and Sullage can be collected through a
single pipeline and then directly connected to Municipal sewer lines. OR Sewage lines shall be taken
separately along the walls and then both connected to Municipal sewer lines. (Reference shall be made
to approved drainage drawings).
4) Vertical stacks (Sewage / Sullage) shall be clamped on both sides of the joint. Clear minimum distance
of 100 mm shall be kept between pipes and wall.
5) If PVC pipes are used as vertical sewer lines, last two pipes shall be of C I.
6) Anti-siphon lines shall be provided for buildings of height more than 15 metres and shall be directly
connected to water closets. Their direct connection to sewage lines shall be avoided.
7) Sewage lines as well as Anti-siphon lines shall be carried to height, at least 6’ above terrace top and
shall be provided with vent cowls.
8) Vent cowls shall be provided with mosquito nets.
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 189 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
9) Both Sewage and Sullage lines, after fixing to wall should appear truly vertical when observed visually
and their connections should be symmetric. Criss-cross connections shall be avoided.
10) All sullage lines shall first be connected to Gully Traps. Gully Traps shall be built inside Brick Masonry
which is plastered afterwards.
11) Inspection chambers in Burnt Brick Masonry shall be constructed at exact location as per drawing
with covers at top.
12) Invert Levels shall be checked with the help of Auto level and got approved from the Engineer. Level
tube shall not be used for fixing invert levels.
13) Chambers shall be plastered, both from inside as well as outside.
14) All branch lines shall join main sewer in the direction of flow sewage. Also branch lines joining
Inspection Chambers shall not be at angle greater than 45_, with the direction of flow of sewage.
15) Inlet / Outlet of chambers shall be plugged with cloth to prevent entry of debris inside. Such
plugging shall be kept till complete erection of drainage line and till pressure testing starts. PCC is
essential underneath chamber.
16) Heavy duty chamber covers shall be used on roads and parking, whereas Light / medium duty
chamber covers shall be used at other places.
17) Channelling inside chambers shall be done smooth or half round SWG pipes shall be used for the
same, if specified by Architect. Chambers, especially at curves shall be properly attended to for providing
smooth curves finished surface inside for smooth flow of sewage within.
18) RCC pipes shall be used for connecting Inspection Chambers. It is ensured that minimum earth
cushion over pipes is 450mm pipes shall be adequately supported underneath by concrete and
minimum slope of 1:100 shall be maintained through the length of sewer line.
19) Inspection Chambers shall be located as near as possible to Gully Trap locations and connection from
Gully Traps to Inspection Chambers shall be through SWG pipes.
20) Jointing of RCC / CI / SWG pipes shall be done with cotton yarn (packing rassi) and expansive grout
and finished with neat cement from all sides. Joints shall then be covered with wet Hessian cloth and
cured for at least 4 days.
21) During jointing operation, C I and SWG pipes shall be supported with masonry supports, whereas
RCC pipes shall be supported by at least two concrete blocks supports to avoid failure of joints.
22) Intermittent ventilation shall be provided for the drainage line as indicated on drawing.
23) Always provide a gas vent for the first & last inspection chamber.
24) In a sewer line a vent shaft should be preferably fixed after every 150 mtrs.
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 190 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
25) A drop arrangement should be done whenever there is difference of 600mm or more in the invert
levels.
26) It is recommended to do bed PCC at the required gradient before laying of the drain line & the line
should be encased properly and proper gradient & alignment is maintained, verified & jointed
satisfactorily.
Post Installation Procedures (External drainage works):
1) After erection of drainage line, all Inspection Chambers and Gully trap as well as Nahani / P traps of
toilets shall be cleaned off mortar, debris and other accumulated construction material.
2) Acid cleaning shall then be carried out from top floor to bottommost floor.
3) Inlet / Outlets of Inspection Chambers shall then be unplugged and entire drainage line shall be filled
with water under pressure.
4) If any leakages are observed, the same shall be rectified. Rectification may involve complete removal
of defective part of drainage line.
5) The drainage line shall then be pressure tested again for ensuring total leak proof flow along the
entire drain line.
6) All holes in masonry shall be rendered with non-shrink grout.
7) Backfilling shall start only after satisfactory testing of drainage line. Backfilling shall be done in layers
with good soil, layers not exceeding 1’ at a time and well compacted by watering soil, if required.
Precaution shall be taken so as not to leave voids below pipes.
Rain Water Drainage:
1) Rain water drainage shall be either C I or PVC or as specified by Architect.
2) Marking of rain water pipes shall be done on external wall surface as per drawing.
3) Outlet positions on terrace shall be marked and holes drilled accordingly.
4) Rain water pipes shall then be fixed along walls so that they appear vertical when observed visually.
5) Clamping and jointing of CI pipes shall be done as specified for sewer down take whereas clamping of
PVC pipes shall be done with PVC clamps at every 6’ along the pipe.
6) Care shall be taken during clamping so as to keep at least 1” gap between plastered wall surface and
pipe surface.
7) Rain water down take pipe shall be terminated at least 9” above finished ground level and provided
with a 45º shoe at bottom end and PVC strainer at top inlet position. Also a tee shall be provided at top
for cleaning purpose.
8) All rain water shall be provided with a concrete block support at bottom end.
9) All holes in masonry shall be rendered with non-shrink grout.
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 191 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
10) A separate drain shall be constructed as per drawing to collect rain water and dispose it into rain
water harvesting system or adjacent nallah or as specified by the architect.
Joinery:
PVC to PVC joint, PVC to C I joint & Open CI to CI joint - Same as mentioned in internal plumbing &
internal drainage.
NOTES:
However it is necessary to follow the Plumbing Consultant’s drawings and instructions. But for general
guidelines, the following dia. of pipes is recommended for the following.
1) Soil Waste -100 to 150mm
2) Waste Water - 75 to 100mm
3) Gas Vents & Anti-syphonage - 50 to 75mm
4) Rain Water - 90 to 200mm
Acceptance of Completed Work
Internal Plumbing & Internal Drainage:
Type of Check Acceptance
Position of: WHB, EWC, Bath tub, Flush tank, As per Architectural Drawing
Boiler w.r.t. FFL and walls.
Fixing of MS painted brackets of WHB Anchor fasteners used
Position of Nahani Trap At WHB outlet and at least 15cm clear from wall
Fittings and fixtures Satisfactory fitting
Holes / Chases in Masonry Rendered with non-shrink grout
All traps Position and level as per Architectural Drawing
Functioning of: Water flow found satisfactory with enough
Ablution tap, Angle stop cock, Long body bib cock pressure
(Kitchen sink), Dry balcony bib cock, Mixer
shower, Flushes, Basin pillar, Basin mixer cock,
Nelson valve, Control valve
All above taps checked after locking No leakages observed
Pressure Testing Satisfactory
External plumbing:
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 192 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
Type of Check Acceptance
External pipelines Truly vertical when observed visually with
adequate distance between wall face and pipes
Pipelines on terrace Along parapet wall and clamp with saddles
Pumping mains Double clamp near joints, bends and turns
Provision of control valves For each outlet near OHWT
Position of foot valve 6” – 8” above tank bottom of UGWT
Manhole cover for UGWT & OHWT Double seal cover type with facility for locking
Leakage observed during gravity pressure testing Corrected and no leakages observed in next
pressure test
Access for water tanks and duct for maintenance Easy
Clamps for CPVC pipes Plastic or as specified by Architect
Fitting of clamps for CPVC pipes Loose for allowing free movement
Rendering of holes in masonry With non – shrink grout
External Drainage:
Type of Check Acceptance
Clamps Not broken and spacing as specified
For vertical PVC sewer lines Last two pipes in CI
Jointing of pipes As specified
Bottom of rain water pipe Provided with 45º shoe and at least 9” above
finished ground level.
Alignment of sewer/rain water pipes along walls. Truly vertical when observed visually
Access to main ducts Easy
Removal of pipes for maintenance Easy
Vertical sewer lines Taken at least 6’ above terrace level and provided
with cowls
Vent pipe above septic tank Taken at least 6’ above top slab level
Rain water pipes Provided with concrete block underneath
Anti-siphon pipe Directly connected to water closets
Leakages Not observed
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 193 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
TOOLS :
A. Drill, Chasing Machine, Spirit Level, Hammer, Drill Bit, Grinding wheel, File, Measuring tape,
Pressure Testing Machine.
B. Chisel, Pipe wrench, Chain wrench, sledge hammer, screw driver, Bench Vice, pipe vice, Die set,
hammer drilling M/c, Mini
C. angle grinding M/c.
Records :
Reference Documents :
ITP Reference No :
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 194 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
METHOD STATEMENT FOR
CONDUTING WORK
SR. EFFECTIVE REV. MSS MANAGER MSS PROJECT CLIENT
CLIENT QA/QC
NO. DATE NO. QA/QC MANAGER SUPERVISOR
CONDUITING
1 SCOPE
This procedure covers erection installation /laying, testing & commissioning of PVC Conduits.
2 PURPOSE
The purpose of this procedure is to provide guidelines for laying of PVC Conduits.
3 REFERENCE DOCUMENTS
1. CONTRACT SPECIFICATIONS.
2. APPLICABLE CODES AND STANDARDS
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 195 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
3. QA PLAN FOR CONDUITING
4 APPLICABILITY
This procedure is applicable for Conduit laying in slab, walls & beams.
5 PROCEDURE
1. RECEIPT AND STORAGE OF CONDUIT:
a. Soon after receipt of conduit inspection shall be carried out to confirm quality, quantity and
size of conduit.
b. Physical verification conduit shall be done to check for any damages.
c. Conduits shall be properly stacked size wise in stores
d. Identification tags shall be provided at every stack.
2. PRE INSTALLATION
a. Shop drawings shall be prepared on the basis of layout drawings and it shall be get approved
from Architect / Client.
b. Before laying the conduit approaches shall be made available to reach to site.
c. Ensure the completion of reinforcement and shuttering & works
d. Before laying of conduits location of beams and wall shall be checked as per drawing.
3. INSTALLATION
a. Marking of conduit layout as per the drawing shall be done.
b. After marking proper size of conduit shall be selected as per drawing. Conduit shall be properly
laid as per route. Coupler shall be provided at the joint of two conduits with solvent cement.
c. Bending of conduit shall be done with bending spring to the required angle.
d. All the junction boxes for fixture shall be fixed as per the drawing
e. All the vertical drops in beam shall be put as per wall location.
f. After laying, conduits and accessories shall be tied with reinforcement by means of binding
wires.
g. All the junction boxes shall be sealed with gunny bags to avoid entry of concrete.
h. Red oxide shall be provided surrounding the junction boxes to get the location of junction box
after removal of shuttering.
i. Proper distance shall be maintained between Electrical & Communication conduit as per
specification.
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 196 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
j. Conduits that are routed ahead of no concreting area shall be marked with circuit Nos with
paint.
k. All the required measurements shall be taken before concreting for preparation of “As Built
drawings”.
Necessary records in various stages of work shall be maintained as per the following format:
Check List for Conduiting:
Records :
Reference Documents :
ITP Reference No :
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 197 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
METHOD STATEMENT
FOR
INSTALLATION TESTING &
COMMISSIONING OF INTERNAL WIRING
SR. EFFECTIVE REV. MSS MANAGER MSS PROJECT CLIENT
CLIENT QA/QC
NO. DATE NO. QA/QC MANAGER SUPERVISOR
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 198 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
INSTALLATION TESTING & COMMISSIONING OF INTERNAL WIRING
1.0 SCOPE
This procedure covers erection, testing & commissioning of wiring
2.0 PURPOSE
The purpose of this procedure is to provide guidelines for pulling of wires.
3.0 REFERENCE DOCUMENTS
1. CONTRACT SPECIFICATIONS
2. APPLICABLE CODES AND STANDARDS - IS : 732
3. QA PLAN FOR WIRING :
4.0 APPLICABILITY
This procedure is applicable for all the buildings wiring.
5.0PROCEDURE
1. RECEIPT AND STORAGE OF WIRES:
a. Soon after receipt of wires inspection shall be carried out to conform quality, quantity and size of
wire.
b. Physical verification wires shall be done to check for any external damages.
c. Wires shall be properly stacked size wise/ colour wise in stores
d. Identification tags shall be provided at every stack.
2. PRE INSTALLATION
a. Conduit shall be made free from any blockages by pulling cord
b. Proper size of wire and colour of wire shall be selected.
3. INSTALLATION
a. Wire shall be pulled with help of G.I. wire. Sufficient quantity of wire shall be kept at both
ends for termination.
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
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METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 199 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
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b.
Wire shall be terminated at DB end with proper size of lugs. Ferruling shall be done to
identify the circuit.
c. Earthing shall be done with green 1.5 Sq.mm for wire all fixtures, fans & sockets. Earth wire shall be
terminated at earth strip at DB end and at earthing terminal at fixture / fan end.
Necessary records in various stages of work shall be maintained as per the following format:
Records :
Reference Documents :
ITP Reference No :
METHOD STATEMENT
FOR
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
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METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 200 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
INSTALLATION TESTING &
COMMISSIONING OF LIGHTING FIXTURE
SR. EFFECTIVE REV. MSS MANAGER MSS PROJECT CLIENT
CLIENT QA/QC
NO. DATE NO. QA/QC MANAGER SUPERVISOR
INSTALLATION TESTING & COMMISSIONING OF LIGHTING FIXTURE
1.0 SCOPE
This procedure covers the method for Installation, Testing & Commissioning of Lighting Fixture.
2.0 PURPOSE
The purpose of this procedure is to provide guidelines for Installation, Testing & Commissioning of
Lighting Fixture.
3.0 REFERENCE DOCUMENTS
1. Contract Specifications.
2. ITP for Installation, Testing & Commissioning of Lighting Fixture:
4.0 APPLICABILITY
This procedure is applicable for Installation, Testing & Commissioning of Lighting Fixture.
1.1 PROCEDURE :
1. RECEIPT AND STORAGE OF LIGHTING FIXTURE :
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 201 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
a. Soon after receipt of lighting fixture inspection shall be carried out to check quantity & type
quality and for any damages to fixture body.
b. Fixture shall be stacked in an enclosed structure.
2. PRE INSTALLATION
a. Layout drawing showing location of lighting fixture shall be drawn and get approved from client
b. Before installation clearance shall be taken from Civil department.
c. Wiring work for the fixture shall be over before installation of fixture.
3. INSTALLATION
a. Location of fixture shall be marked as per the approved layout drawing.
b. Fixture shall be fixed as per this marking with required accessories.
c. Termination of wires shall be done.
d. Earthing wire shall be properly terminated to earth terminal given on fixture.
4. TESTING, PRECOMMISSIONING & COMMISSIONING
a. Wiring of fixture shall be properly checked for its tightness.
b. Insulation resistance of fixture shall be checked with 500V megger.
c. Suitable type of lamp shall be fixed.
d. After completing above fixture can be charged.
Necessary records in various stages of work shall be maintained as per the following format:
Check List for Installation, Testing & Commissioning of Lighting fixture :
Records :
Reference Documents :
ITP Reference No :
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 202 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
METHOD STATEMENT FOR LAYING OF
SCREED CONCRETE
SR. EFFECTIVE REV. MSS MANAGER MSS PROJECT CLIENT
CLIENT QA/QC
NO. DATE NO. QA/QC MANAGER SUPERVISOR
LAYING OF SCREED CONCRETE
1. INTRODUCTION
This document describes the methodology for the laying of screed concrete in basement area. To
meet technical requirements, suitable construction methodology has been adopted in all the
works to ensure quality and safety apart from the speedy construction. A commitment to
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NAME:
maintain the highest possible standards has played a key role in finalizing the construction
methodology for the construction of ground floor slab.
2. SCOPE : Scope of the work includes screed concreting of basement floor slab .
3. REFERENCE
Following documents / drawing / codes have been referred for the preparation of this method
statement:
a. Civil Structural Specification
b. Structural & Architectural drawing of ground floor slab
4. Brief Methodology
The major construction activities for the screed concreting of basement floor slab are as follows:
C. Form Work
Shuttering required for 300 mm thickness if required for the predetermined periphery stripe &
deshuttering shall be done on the next day.
D. Concreting :
i. Transportation of Concrete
All concrete will be transported from the batching plant to the construction site in transit
mixers of 6 cum capacity & from site to the required place it shall be pumping or placed
directly from chute.
ii. Placing of Concrete:
As per the specification grade of concrete for the slab is M10 approved mix design.
Proper pipeline is engaged or appropriate placing arrangement shall be made to the
site.
Concreting shall be done stripe / bay wise , alternate stripe / bay shall be concreted on
same day & remaining alternate shall be on next day.
Width of each bay shall be ranging from 2.0 to 3.00 mtr. As per the space available.
Required no. of needle vibrators shall be deployed for concreting.
Next day of concreting each stripe / bay shall be having groove cutting of depth 10 to
15 mm at distance of 2.00 to 3.00 mtr. c/c.
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Joint between two adjoining stripe / bay shall be cleaned on next day after concreting
of both the stripe / bay are completed.
Suitable polymer based joint filler is filled in the joint between two stripe / bay &
groove made in the individual stripe / bay.
Levelling instrument will be set up for checking the top level of the screed during
concreting.
Same sequence of concreting to be followed for the balance part of slab; delayed
finishing will be done in order to avoid shrinkage cracks.
Records :
Reference Documents :
ITP Reference No :
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METHOD STATEMENT FOR STEEL
STRUCTURE FABRICATION & SITE
INSTALLATION WORK
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Page 206 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
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CONTRACTOR
NAME:
SR. EFFECTIVE REV. MSS MANAGER MSS PROJECT CLIENT
CLIENT QA/QC
NO. DATE NO. QA/QC MANAGER SUPERVISOR
STEEL STRUCTURE FABRICATION & SITE INSTALLATION WORK
1. OBJECTIVE
The scope of these procedures covers the:
Fabrication and installation as per the approved drawings;
Fabrication of Steel Structures (Section A)
Surface preparation
Painting
Erection of Fabricated Steel Structures. (Section B)
Purpose
To ensure that all phases of steel member’s Fabrication and erection are managed as per Technical
Specifications and Client requirements.
1.2 Responsibility
Six Construct is responsible for obtaining required authority approvals and execute the works to
comply with project quality and safety standards.
This section is intended to clearly define the responsibilities and communication procedure
between all the key personnel involved in the activities.
Project Manager
Is responsible for the overall project activities;
Is responsible for the Production activities related to the scope of work;
Is responsible to arrange the work force, machinery and equipment required for the set
production targets;
Is responsible to monitor and assure the material availability for erection activities;
Is responsible to plan the work force and material requirement for production in coordination
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with site engineer and erection superintendent responsible, to generate and update the
erection status, calculate and estimate the costs and budgeting and to arrange the materials
required for fabrication;
Is responsible to provide weekly production reports to the main contractor project manager;
Ensure project erection the targets are well maintained in terms of quality & quantity
requirements;
Site Superintendent.
Responsible for erection and the day to day site activities, in organizing and handling of manpower and
equipment’s in order to achieve the required performance output both in terms of quality and
quantity within the hours worked for the project;
To carry out specifically the instruction given by the Project Manager and ensure that the work being
carried out is in accordance with company procedures and also that safety regulation are observed by
the men under his control;
To ensure that the workforce under his control, report to work punctually and carry out the work
efficiently without any obstructions;
Ensure the fabricated steel members issued to site are handled with proper care and secured safely
while offloading from and to site. Special care shall take to prevent deformation and paint damages
while site handling;
Coordinate with mechanical draftsmen for better understandings prior start erection activities;
Coordinate with QA/QC before and after erection stages to ensure proper execution in terms of time
and quality of work;
Report to the project manager.
Site Supervisor / Foreman;
Conduct daily tool box talks (TBTs);
Control, monitor and Implement safety inductions corroborated with Site safety officer;
Control and Monitor regularly the lifting equipment’s: visual inspection to assure its qualities the
integrities of each of the following: lifting belts, shackles, lifting chains, eye bolts, chain pullers etc.;
Supervise and monitor the erection process full time;
Guide the riggers to ensure that are using proper signals, with respect to crane operators and steel
erectors;
Plan in advance the required erection equipment’s: mobile cranes, fork lifters, man lift and etc.
Read, interpret, follow / implement the approved drawings related to Erection activities corroborates
with Shop drawings;
Follow and Implement strictly the project Approved procedures;
Report all incidents and accidents to the project stakeholders;
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Coordinate with QA/QC before and after the fabrication stages;
Report the daily production status to fabrication coordinator;
Request Coordinate with site surveyor for installed steel structure components from site
representatives;
Generate RFI to QA/QC department for all online and final inspection.
QA/QC Engineer;
Maintain the quality level of the company and its product;
Involved in developing systems to ensure products or services are designed and produced to meet
or exceed customer requirements and expectation;
Responsible to prepare project Quality Plan, Inspection Test Plan and other project documents.
necessary client submittal for review and approval;
Coordinate with approved TPI for material inspection whenever is applicable;
Responsible for all Quality Control Inspections of fabrication and erection works;
Coordinate with welding TPI for NDT’s requirements whenever is required site weld;
Ensure and interpret the NDT’s reports in order to assure right interpretation whenever is
applicable;
Take corrective actions to production department if any deviations from the technical
specifications;
Raise Non Conformance Records, and ensure appropriate corrective action and close out;
Coordination with project subcontractors in order to assure the quality requirements as per project
technical specifications;
Compliance as per approved ITP with respect to project specifications.
Safety Officer
Generate and conduct daily TBT prior start of work in coordination with site superintendent;
Coordinate with site erection in-charge and site engineer/superintendent for HSE requirements and
necessary work permits at the site, Prior to start of erection activities;
Responsible for monitoring and assessing hazardous and unsafe situations and developing measures to
assure personnel safety;
To correct unsafe acts or conditions through the regular line of authority, although the HSE Officer may
exercise emergency authority to prevent or stop unsafe acts when immediate action is required;
Ensure the site Safety and Health plan is prepared and implemented;
Responsible to investigate all accidents and Incidents. if any, document the same with proper related
reports and necessary action Plan;
Establish and maintain an up-to-date library on relevant publications, legal regulations and instruction
concerning Safety Standards. Ensure company safety policy statement is displayed and all employees
are aware of the same;
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NAME:
Conduct safety induction training to all employees;
Promote and comply to all HSE requirements at all times, through the safety management system
procedures and enhance continual improvement;
Generate Check list for all lifting equipment’s; like mobile cranes, man lifts, chain pullers, lever blocks,
lifting belts, lifting chains etc. and monitor on daily basis or whenever is required to ensure they are in
Safe functional condition;
Temporary scaffolding should be monitored daily or whenever is required. Verify the tag certificates
validity and ensure it’s done through certified scolders and checked by certified scaffolding foreman
prior to any erection;
Daily monitoring and implementing the PPE requirements to all staff and workers reported to the site:
Safety shoes, safety helmets, adequate coveralls, safety glass, hand gloves etc. special attention
should be taken for the employees working at heights, and should wear safety harness to prevent
potential fall.
1.1 Location of Works
KAMOA, MSS shop fabrication;
1.4 Referenced Documents
Contract specification;
Material Submittal;
Occupation, Health, Safety and Environment Management;
Project Quality Plan;
Method Statement for Steel Structure Fabrication;
ITP for Steel Structure fabrication;
Health, Safety and Environment
2.1 Health and Safety
Safety & Housekeeping
Safety is as important as production, quality and cost control and is an essential partner to safe and
efficient operation. Housekeeping shall be carried out in a regular basis.
General
Since erection of structural steel is carried out at heights, every person engaged in this work should
make every effort to prevent any accident, flying of materials, Fire and Explosion.
Safety Gadget Person
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All workers to wear their own PPE while working on the job site;
All people working at elevated place, should tighten their own safety harness and the rope shall be
hooked to the nearest secured fixed support, which is higher than the working platform;
Man lift to be used for tightening of bolts, as well as welding work if any;
Safety Net shall be installed at the lower portion of steel truss member, if required;
Dangerous work such as lifting, installing and removing scaffolding shall be isolated by demarking the
area with barricade tape;
Counter Measure against the Strong Wind
The lifting work should be suspended when the strong wind is blowing over 32 Km/Hrs (20 Mph) and
scaffolding installed at the high place above the ground should be fastens strictly with nearest
structural for safety;
All cranes shall have to be sheltered and anchored on boom down with its turntable on lock-mode
during strong wind;
Mobile cranes, articulated and scissor lifts should be brought down.
Tool Box Meeting
Regularly all workers should attend consolidated morning meeting and after finish, they attend group
wise separate toolbox meetings , if in case misunderstandings;
At the tool box meeting, they shall discuss safe work practices, general awareness, work schedule, work
procedure, etc.
2.2 Environment
Aspects:
Use of plant machinery and equipment.
Impact:
Potential source of dust that will affect taxiway, establishments and buildings in the vicinity;
Contamination of soil from equipment;
Air pollution (crane or trucks exhaust emissions).
Mitigating Measures:
All the equipment & tools used for the work should be in good working condition, properly maintained
and certified by the 3rd party;
No equipment emitting excessive black smoke shall be permitted to operate on the construction site.
Regular plant and equipment inspections shall also monitor;
Oils will be sampled at the earliest opportunity and drained and disposed of through a licensed
undertaker;
All environment issues shall be reported to the engineer and the safety department for further
investigation;
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Tool boxes talks shall be given regularly to reiterate the environmental hazards of an existing work
activity or to high light the risks of a new activity. All briefings and tool box talks are to be conducted.
3 Materials, Equipment and Manpower
Materials:
Safety equipment (PPE, safety cones, mesh and barriers, warning tapes);
Steel structures.
4 Quality Assurance and Quality Control Measures
To allow the Consultant to inspect the Works, the Contractor shall give the Consultant a minimum of
24 hours’ notice of carrying out the following activities on site;
All Laying of steel structures elements, shall store in dry conditions;
For levels and elevations controlling, surveyor team will be deployed to site for horizontal and vertical
alignments;
QC Inspector will independently carry out surveillance of the works using approved ITP;
Approved ITP should be implemented following approved erection drawings.
5. Sequence of Works
Drawing and document;
Material procurement;
Receiving materials;
Material storage;
Tools, equipment & machines;
Marking;
Cutting cleaning and surface preparation;
Drilling/machining and surface preparation;
Surface finish;
Non-destructive examination;
Correction of strain/straightening;
Final inspection and release for galvanizing &painting;
Surface preparation and galvanizing;
Surface preparation and painting;
Transportation.
5.1. Fabrication Process
5.2. Drawing & Document
The design drawings and documents calculations is provided by “as per Contract”;
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Shop and erection drawings to be provided by “as per Contract”.
5.3 Material Procurement
Raw materials to be procured by “as per Contract”, in line with the project specification.
Materials to be supplied by “as per Contract” in accordance with the design specifications and project
requirements.
5.4 Receiving Materials
Upon delivery of bulk materials, the material shall be inspected for shape, dimension, and
confirmation of quality and appearance by cross-checking against the order list;
If the inspection cannot be conducted upon delivery, the inspection shall be conducted at the earliest
possible;
Receiving inspection shall be recorded in form “Material Inspection Report”.
5.5 Material Storage
All material shall be separately stored according to shape dimensions, grade and class;
Materials to be stored shall be protected by wood slipper to prevent material’s pre and post
fabrication and welding distortions / sagging;
The storage shall be in such ways, to enable easy identify of material tractability / identification no
like: HT no, marks no, item no. etc.
5.6 Tools, Equipment & Machineries
All measuring equipment used during fabrication and erection should be calibrated and recorded in
master list to enable easy traceability and equipment status ;
All Lifting Tools/Equipment and Lifting Machineries should be calibrated and recorded (Third Party
Inspection);
Machineries like (CNCs, manual or semiautomatic gas cutting machine, saw cutting machine, shearing
machine, etc.) is well maintained and corroborated with a preventive maintenance plan.
5.7 Marking
Straightening of plates and structural steel shall be properly performed prior to lay-out;
Marking-off works shall be prepared properly in consideration of acceptance Criteria, welding strain,
shrinkage and materials, for all markings which involving more than two dimensions;
Part or assembled items can be marked manually or automatic in CNC system.
5.8 Cutting, Cleaning & Surface Preparation
Ensure the dimensions of the plate is maintained as per drawings;
Ensure the flatness of the plate is within acceptances criteria;
Due to flame cutting system undercuts might occur. As rectification, local buildup touchup and flush
grinding shall be applied;
Fit-up will carried out as per drawings;
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Maintain proper connection between base plates and roof steel frame elements;
Ensure the fillet weld joint is achieved as per IFC drawings;
Welding shrinkage, deformation and finishing allowance shall be considered for cutting;
Cutting works by means of shearing, sawing, gas cutting, etc., shall be performed using mechanical
guided tool as much as possible. During cutting all necessary safety precaution to be applied;
Sharp edges of all materials, shall be rounded and made smooth;
Generally all bracings and its attachments shall be cold cutting by bend saw cutting machine and or
hot cutting by CNC flame / plasma cutting machine;
All welded joints should be ground smooth / cleaned / de burring / free of spatter.
5.9 Drilling / Machining & Surface Preparation
For bolted connections of steel structures, gusset plates, base plates, etc. holes are drilled by either
cold drilling or punching;
Cold drilling method shall be used for thickness above 16 mm, and in case of wall thickness less
than 16mm punching method can be applied;
All holes shall be at right angle to each surface of the materials with the exception of those
particularly specified in the drawings;
Any defects such as burrs, turn strain etc. around the holes shall be removed.
5.10 Fabrication / Fit up
Proper measuring tapes, tools shall be used during fit-up works;
Tolerance for the fabrication of the steel structure shall be maintained as specified on the applicable
fabrication drawing and or inspection procedure document stipulated in the data sheet and control
drawing – reference code: SANS 2001-CS1
Fit-up with temporary support is acceptable if required, but all supports should be properly removed
after full welding;
Fit up must be inspected by QC prior to welding;
Fabrication sequences for main structural components:
Roof steel structure and its accessories;
For quality and mismatching assurance trial assembly is recommended prior site delivery;
QC inspection report will be performed and recorded as per approved ITP / check list.
5.11 Workshop Welding Works
All welding should be carried out as per approved Drawings and WPS;
Welding rods / filler wires shall be used for welding should be heated to desire temperature as
recommended by the manufacturer prior to use;
Suitable measures shall be taken to reduce deformations and shrinkage by welding;
In windy places, welding shall be performed under condition of shielding wind.
Special care should be administered in case of wind, during flux cored arc welding (FCAW). And
welding should be stopped in case of wind speed more than 2 meters per second.
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After welding proper treatment shall be performed to welded surfaces and any defects such as over
lapping, unevenness of bead, undercut, pits, slug’s inclusion, crater, lack of welding etc. shall be
rectified. When a crack is detected on the weld metal, the defective surface on the weld metal shall
be eliminate of all the length of welding line and its portion shall be gouged out and shall be re-
welded .
5.12 Surface Finish
Weld spatter, arc strike, fluxes and sharp edges shall be removed by grinding during the finishing works.
5.13 Non Destructive Examination (NDE)
NDE are performed by certified third party / QAQC Dept. as per approved ITP.
5.14 Correction of Strain / Straightening
Any strain caused during fabrication works, especially by welding shall be corrected by means of
mechanical method so as not to damage the surface of materials. Press machine and bending machine
can be applied;
Hot straightening shall be avoided.
5.15 Final Inspection & Release for Painting
All inspections should be done as per approved ITP;
Final Inspection shall be conducted after completion of the fabrication process prior to releasing the
items for Galvanizing / Painting;
The inspection will be conducted by QC;
As per approved ITP, main Contractor QC representatives should ensure required intervention check.
5.16 Surface preparation & Galvanizing
Surface Preparation and galvanizing of steel structure will be carried out by an external / internal service
provider;
Galvanizing system will be followed, as per the project specification and approved ITP.
5.17 Surface Preparation & Painting
Surface Preparation and Painting of steel structure, shall be carried out by the paint applicator;
Painting Schedule or Coating system will be followed as per approved ITP.
5.18 Transportation
Proper transport shall be used for shifting the steel structure components from Shop to the required
sites;
During transportation wood pieces shall be used between steel structure components to prevent
friction and paint damage;
Special transporting permit shall be obtained, if in case the transporting load exceeds the allowable
transporting limits w.r.t height, width and length.
5.19 Workshop Material Handling & Storage
Certified lifting belts, shackles, chains and slings shall be used in the handling process;
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Materials are stored in such a way to ensure, material identification is visible and readable for
traceability;
On receipt the raw materials shall be carefully unloaded and examined for defects, checked and sorted
according to its erection sequence requirements. The steels must be supported with wooden skids
above clean and dry ground;
Trusses / Rafter and other members after fabrication, shall be supported properly to avoid potential
deflections;
All steel structure members shall be stored and handed in such a manner, that it is not subjected to
excessive stress, which may cause damaged;
Bolts shall be stored in dry and clean containers covered with water proofed sheets. Packages of bolts
shall be opened shortly before it will use;
Any materials found damaged or defective shall be quarantined separately and the damaged or
defective portions shall be identified by paint applied in distinct color.
6.0. INSTALLATION OF STEEL STRUCTURE
6.1. Erection Process
6.1.1. General Requirements
Safety of workers is always the priority throughout the execution of the work.
The work shall be performed in accordance with this document, structural drawings, plot plan and other
documents prepared and approved by the consultant.
All Structural members delivered shall be stored in the designated storage area, near the erection area.
Hoist and transport of the equipment shall be carried out by the skilled workers having sufficient
experience, rigging and rope – knotting work in compliance with safety regulations.
Necessary permission to use fire shall be obtained prior to the use of fire and the responsible supervisor
shall attend throughout the completion of the work.
No welding, gas cutting and other similar activities will be accepted in area designated for painted steel
structure.
If, in case of rework, the structural component subjected for rework shall be removed and shifted to the
designated area for fireworks; the activity shall be supervised by a fire man and the area should have
sufficient quantities of fire extinguishers.
Only experienced and certified welders shall carry out welding works.
Adequate scaffolding and man lifts must be provide for workmen to reach all parts of the work safely.
All scaffolds, temporary access and ladders shall be inspected by the Safety Officer prior to its use.
All tools and equipment must be kept in safe working condition and shall be inspected regularly.
6.1.2. Site Material Handling & Storage
Certified lifting belts, shackles, chains and slings will be used in handling process.
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 216 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
Materials are stored in way, in which, its identification is visible and readable for easy access and
materials traceability.
After receiving the material at Site, the fabricated materials shall be carefully unloaded and examined for
defects, checked and sorted according to its erection sequence requirements. The steels must be
supported with wooden skids above clean and dry ground. Trusses / Rafter and other members, shall be
supported properly to avoid unnecessary deflection.
The steel structure members shall be stored and handed in such a manner that none of the members are
subjected to stress, which may cause damaged.
Bolts shall be stored in dry and clean containers covered with water proofed sheets. Packages of bolts
shall be opened shortly before it will use.
The fabricated material shall be verified with respect to markings on the match marking drawings and
shipping list supplied. Any materials found damaged or defective shall be stacked separately and the
damage or defective portions shall be identified by paint applied in distinct color .
6.1.3. Re-Survey
Prior to start the erection work, re-survey shall be conducted in the presence of the Contractor’s site
dimension surveyor and anchor erector to determine the accuracy of grid lines dimensions, anchor bolts
distance and plumpness, level and elevations.
Site surveyor will be provided by main contractor.
Non-compliance shall be corrected prior to erection works.
All reference and control points shall be fixed near the work site for facilitating the erection work.
All anchors bolt and base plate’s coordinates are generated and confirmed by contractor .
6.1.4. Hoisting Steps & Lifting Plan
Hoisting operation shall be carried out in accordance with the following procedure:
Positioning of lifting equipment, base conditions under out – rigger, operation circle, etc. shall carefully
be examined before the work.
Before winding up, check all the condition, such as crane positioning, wire arrangement, etc.
Wind up a little to check the loading conditions. Check the whole situation carefully.
If any dangerous and / or abnormal condition is observed, immediately pull down the member
Make necessary reinforcement or suitable safe arrangement.
Proceed with the wind-up and transfer operation slowly and carefully.
Hoisting work shall not be interrupted under any dangerous situation. (Example: Interruption during
hanging situation).
Hoisting or pulling down shall be directed by single responsible supervisor. Whistle and hand signal shall
be used in regular method. Further, a line – system to transmit the instruction thoroughly form the top to
bottom level workers shall be organized.
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Page 217 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
Erection shall not be executed on rainy days, in strong windy, sandstorm, and after sunset without
adequate lighting.
Erection sequence shall be follow as per the client priority and project specification.
Certified rigging staff to be provided in coordination with main contractor.
6.1.5. Sequence
Embedded base plates;
Inclined bracings;
Roof trusses elements;
Roof bracings elements;
Facade steel structural frame.
The above erection details and sequence are provided to ensure the structural stability, alignment of the
columns and beams while erection process. All the Steel structural installation should be carried out as
per the approved erection drawing.
6.1.6. Bolting
Field bolt connections shall be accurately fitted before the bolts are inserted. The number of bolts for
temporary setting shall be more than 1/3 of the specified number of bolts of each part. Finished bolts
shall not be used for temporary bolting.
Permanent bolts tightening torques value should be maintained.
For bolts tightening shall use standard calibrated torque.
During the bolting scaffolds or articulated man lift will be used.
Calibration of articulated man lift and service certificate should be available during erection.
Qualified and trained operator will be used to operate the articulated man lift.
Bolts tightening should be provided as per approved torques values reflected in the erection drawings.
6.1.7. Site Welding
Site welding generally is not applicable except extreme situation.
Wherever required site welding should be in accordance with AWS D1.1 standard.
All sites welding shall be performed in accordance with requirement for the shop welding, except for
such requirement which applies specifically to shop condition only.
Where steel has been delivered painted, before the field welding, the paint shall be removed at least
50mm on both sides of the joints.
All post weld spatters should be removed;
Welding irregularities and undercuts are not accepted.
All bevels and joints should be verified and released for welding after QC inspector inspections and
reports.
All field welding reworks should be under the direct supervision of welding supervisor / foremen
corroborated by specialist if need.
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
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METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 218 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
In case of site welding required – area to be barricaded area and ensure necessary fire extinguishers &
fire proofed tarpaulin for welding activity.
Welder will wear all safety PPE (apron, leather gloves …etc.)
Underneath of the welding material cover with fire blanket.
Depute fire watchman during the welding operation.
6.1.8. Hot Work
Prior start any Hot works where is involving open fire, proper inspection and clearance, work permit
should be provided by safety officer.
Grinding, cutting and welding process are considered as hot work process.
All hot work process will be done in barricaded area.
Proper grinding and cutting tools will be maintained in the maintenance report.
All machine service report will be given upon on request.
All consumable will be kept in the separate container.
Machine will be checked periodically by the maintenance team.
All Electrical wire and cable will be check by electrician.
Color code of each item will be checked and marked.
Prior to start the work, work permit should be obtained by site superintendent.
The hot work area should be supervised continuously during the activity by the supervisor /foremen.
Fire extinguisher should be kept where the hot work is carried out.
Inspection to be carried out after hot work.
6.1.9. Working at Height
All workers shall be protected from falls of 1.2 meter or more by the use of an approved fall protection
system.
Roof edge barriers (or scaffolds) must be erected to prevent people and materials falling.
Calibrated Safety harness will be used for working at height.
Calibrated certificate of safety harness will be given upon request.
All harness should by check and monitored by the foreman.
Damaged harness will be considering as not useable and marked as RED.
When working at height –Life line will be made and checked with safety team.
Once the worker reached the life line, he will hook himself to it.
All working at heights is supervised by Safety Officer.
Tool box meeting to be carried out before start the work.
6.1.10. Use of Mobile Elevated Work Platforms
For bolting purpose of beams, will use articulated man lift or proper scaffolding.
Scaffolding will be inspected by the Safety Officer and will be accordingly TAGGED.
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METHOD STATEMENTS
TITLE:
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NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
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NAME:
Only qualified articulated man lift operator will allowed to operate the machine.
All articulated man lift moving will be controlled by flagman.
Articulated man lift will be serviced periodically.
Service and maintenance report of articulated man lift will be given upon request.
Maximum height of 22meter long articulated man lift will be used.
6.1.11. Painting (Touch up)
Immediately after the inspection of the field welding, the connecting joint shall be painted with paint
specified for the project. Scratches or damage paint during handling and lifting shall rectify.
6.1.12. Grouting
Grouting shall be carried out only after a sufficient portion of the steel works including columns, trusses,
bracing, etc. has been properly aligned, leveled and plumbed.
Immediately before grouting, the space under the plate and around the bolts shall be thoroughly cleaned
and free from any foreign matters. These activities shall be performed by contractor.
Only approved grouting material shall be used at site.
6.1.13. Safety & Housekeeping
Safety is as important as production, quality and cost control and is an essential partner to safe and
efficient operation.
Housekeeping shall be carried out in a regular basis.
6.1.13.1. General
Since erection of structural steel is carried out at high place above the ground, every person engages in
this work should make every effort to prevent an accident from falling / flying materials / fire and
explosion.
6.1.13.2. Safety Gadget Person
All workers to wear their own PPE while working on the job site;
All people working at elevated place, should tighten their own safety harness and the rope shall be
hooked to the nearest secured fixed support, which is higher than the working platform;
Man lift to be used for tightening of bolts, as well as welding work if any;
Safety Net shall be installed at the lower portion of steel truss member, if required;
Dangerous work such as lifting, installing and removing scaffolding shall be isolated by demarking
the area with barricade tape;
Third party not concerned with the work shall not be allowed to come into the working area.
6.1.13.3. Counter Measure against the Strong Wind
The lifting work should be suspended when the strong wind is blowing over 16m/s and scaffolding
installed at the high place above the ground should be fastens strictly with nearest structural for safety;
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
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DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 220 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
All cranes shall have to be sheltered and anchored on boom down with its turntable on lock-mode during
strong wind;
Mobile cranes, articulated and scissor lifts should be brought down.
In case of heavy wind, rain, fire and other calamities, emergency access ways should be identified and
provided and visible marked by main contractor safety departments for emergency exit of erection team.
6.1.13.4. Erection Execution Process
As per the Erection Drawing No# and the safety regulation will be follow and monitored.
6.1.13.5. Tool Box Meeting
Regularly all workers should attend consolidated morning meeting, and after finish, they attend group
wise separate toolbox meetings , if in case misunderstandings;
At the tool box meeting, they shall discuss safe work practices, general awareness, work schedule,
work procedure, etc.
Records :
Reference Documents :
ITP Reference No :
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 221 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
METHOD STATEMENT
FOR
PAVING / FLOORING
SR. EFFECTIVE REV. MSS MANAGER MSS PROJECT CLIENT
CLIENT QA/QC
NO. DATE NO. QA/QC MANAGER SUPERVISOR
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REV NO.: 00
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METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 222 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
PAVING / FLOORING
1.0 PURPOSE
The purpose of this specification is to enable the Contractor to perform various construction activities
involved to carry out the work as per the needs of the Consultant /Owner. The various activities
involved for carrying out concrete road / paving work are filling if required, compacting, formation of
sub-base, concreting work and providing joints at intervals as specified.
2.0 SCOPE
This specification describes the procedures to be followed and the parameters to be adopted in the
execution of works required for the construction of concrete factory roads /paving, including supporting
layers. The road layers shall be as shown in the drawing.
3.0 TECHNICAL REQUIREMENT
3.1 GENERAL
The concrete paving / road shall consist of concrete road /paving slab constructed over a sub base of
compacted rubble soling or Sand or layers of Wet Mix Macadam as specified in Specification for asphalt
road work, type as specified in the drawing. A lean concrete levelling course shall separate the
pavement slab and the sub base. The Macadam system of construction, i.e provision of cross slopes in
the sub grade followed by layers of constant thickness, shall be adopted. An adequate number of
properly detailed joints to take care of thermal and shrinkage stresses shall be provided. The work shall
be carried out strictly as per this and other related specifications, in accordance with drawings and
relevant SANS codes, specification for flooring works. Conflicts in recommendations shall be referred to
the Owner/consultant for resolving. However, in general, in case of conflict between this specification
and SANS codes, specification for paving / flooring works then the recommendations of this specification
shall govern. In case of conflict between this specification and design basis / job specification, the design
basis / job specification shall govern.
The cross section of the concrete carriage way part shall be as per this specification; the shoulder shall
be as per the drawing or as directed by the Owner/consultant.
The sub grade and sub base shall be done in the first stage and in the second stage the PCC and the
Concrete slab part of the paving / flooring shall be done in the after construction traffic has reduced and
after getting permission from the Owner/consultant .
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MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
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PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 223 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
3.2 SUB GRADE & SUB BASE
3.2. a. SUBGRADE PREPARATION
Before carrying out the rubble soling / sand / wet mix macadam and Laterite the subgrade shall be
dressed to a cross slope in directions as per the drawing, starting from the centreline in case of roads,
watered and rolled to line and level as per drawings and to a strength, checked by CBR or Plate Load
tests (one test every 200 m), of not less than one of the following :-
i) CBR = max.15 % (CBR value should be taken on the soil surface below the PCC layer of the road as
recommended by the Owner/consultant) ii) Modulus of subgrade reaction, K = 6.5 kg/cm³ Soft patches
and depressions shall be rectified by adding extra material and consolidating.
3.2. b SUB BASE
The sub base shall consist of well compacted rubble soiling / sand / wet mix macadam with
interstices filled with Laterite; type as specified in the drawing as directed by owner/consultant; it shall
be topped by a lean concrete levelling course. The soling shall be constructed as per the drawing,
maintaining specified camber and cross slopes, as per Asphalt roads specification. All defects that might
have resulted from movement of vehicles during plant construction phase shall be repaired prior to
commencing (in differed construction) the second stage of blinding concrete work. The surface of the
sub base shall be moist when placing the levelling course. If required, it shall be saturated with water 6
to 10 hours in advance of placing concrete. Surface uneven ness of the levelling course shall not exceed
10 mm under straight edge. Reference as per Asphalt roads specification. In the second stage the
differed construction of construction shall be only for concrete road and not for concrete paving work.
3.2.c The uniformly compacted sub base shall extend at least 30 cms on either side of the width
to be concreted and shall be properly drained. The sub base shall be prepared and checked at
least 2 days in advance of concreting.
3.3 CONCRETE PAVING
3.3.a GENERAL
For Concrete road with vehicular traffic minimum 200 mm thick or as shown in the drawing, reinforced
concrete slab of M35 grade unless noted otherwise, finished with boomer textured antiskid
finish .Reinforcement and layers shall be as shown in the drawing. The concrete paving shall be as per
the drawing.
3.3.b CONCRETE
The concrete shall be machine mixed and proportioned by weigh batching and laid in panels of
maximum 3.5 x 30 m. At least 48 hrs. Time gap between casting of adjacent panels shall be allowed.
Each panel shall be laid in a single pour. Cement content & water cement ratio shall be as per Plain &
Reinforced concrete specification. Plasticisers shall be used to obtain the necessary workability. The
concrete shall be laid in two layers, each layer being compacted with needle, plate or beam vibrators as
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Page 224 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
appropriate. Care shall be taken to avoid over vibration and appearance of water/laitance on the
surface. Time lag between bottom layer and top layer shall not be more than 20 minutes. Variation in
thickness shall not exceed -0 to +10mm. Cement shall be ordinary Portland cement of grade 53. Curing
shall be carried out for atleast 14 days by ponding. However, for the first day after casting, curing with
wet hesian cloth shall be carried out. Relevant details of Civil specification for Plain and Reinforced
Concrete, shall be adhered to. The concrete road will be opened for traffic when the concrete attains the
required strength or after 28 days of curing, whichever is later.
3.3.c FORMWORK
Formwork shall be of steel plates having depth equal to the thickness of the pavement and provided
with suitable holes and sleeves to allow the dowel bars to pass through and be held in a perfectly
horizontal position. Suitable arrangement shall be made to ensure that there is no movement of dowel
bars along the sleeve during placement and vibration of concrete. Formwork shall be fixed in a perfectly
vertical position.
3.3.d SURFACE
Pavement surface shall be made skid resistant by imparting a textured surface (broomer finish) to it.
This shall be done by drawing a 450mm wide wire brush, made of 32 guage wire, across the pavement,
perpendicular to its longitudinal axis after partial setting of the concrete. Care shall be taken to avoid
producing depressions/indentations and unevenness on the surface. Average depth of texturing shall be
1 mm. Limit of surface irregularity, measured with 3m straight edge, is 5mm.
Number of irregularities exceeding 5mm, but in no case more than 7 mm, shall be no more than 20 in a
road length of 300m.
3.4 JOINTS
3.4.a GENERAL
Two types of joints shall be provided - contraction and construction/expansion. The former shall be
only of transverse type, made by machine cutting and provided primarily for relieving shrinkage stresses.
Latter shall be both transverse and longitudinal, shall be performed and shall serve the purpose of
dividing the pavement into panels that can be conveniently poured without interruption as also allowing
thermal expansion, if any. Joints shall be provided strictly as per drawings. Material for joint filler shall
be provided to suit IS 10566.
3.4.b CONTRACTION JOINTS
Contraction joints shall be provided at every 6m along the length of the road in a transverse direction
by machine cutting grooves of 3 to 5 mm width and 50mm depth into the concrete within 48 hrs. Of
casting. At the end of the entire roadwork, these shall be filled with cold applied bitumen joint sealing
compound, poured after cleaning the groove with wire brush and compressed air and made flush with
the pavement surface.
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3.4.c CONSTRUCTION/EXPANSION (C/E) JOINTS
Longitudinal C/E joint dividing the concrete road / paving into 2 or 3 equal parts along the width shall be
provided continuously along the length of the concrete road/ paving. Transverse C/E joints shall be
provided across the pavement at every 30m. Each resulting panel of maximum 3.5 m x 50m shall be cast
in a single pour, i.e. there shall be no further construction joints within any panel.
C/E joints shall be formed by placing 12mm thick bituminous pre-moulded joint filler between adjacent
slab panels. M.S. tie round bars conforming to IS 2062 of 20mm dia. x 1000 mm long and at 300mm c/c
wherever directed including handling, wrapping with paper for half length & HDPE pipe 50mm dia. x
175mm long with HDPE end cap over dowels at construction joints & fixing cotton filling in plastic sleeve
& painting to 350mm at one end
Top edges of concrete slab shall be chamfered (10mm x 45) or rounded (rad = 10mm) at transverse C/E
joints.
The joints part above the bituminous pre-moulded joint filler board shall be sealed with hot applied
bituminous joint sealant.
3.4 d ISOLATION JOINTS
Isolation joints shall be provided where slab a burs columns, walls, flooring, etc. The joints shall be
formed with sand and bitumen filler on top
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PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 226 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
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METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 227 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
METHOD STATEMENT FOR SURFACE
PREPARATION AND COATING
PROCEDURE
SR. EFFECTIVE REV. MSS MANAGER MS PROJECT CLIENT
CLIENT QA/QC
NO. DATE NO. QA/QC MANAGER SUPERVISOR
INDEX
CLAUSE No. DESCRIPTION
1. Scope
2. Purpose
3. Area of Application
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4. References
5. Paint Storage
6. General Requirement
7. Preparation of Surface for Painting
8. Adhesion Test
9. Environmental Condition
10. Painting Application
11. Painting Data
12. Stripe Coat
13. Touch-up and Repair
14. Repair Procedure
15. Safety
16. Inspection
17. Documentation & Record
STRUCTURAL STEEL CORROSION PROTECTION
1.0 SCOPE
The scope of this procedure covers the general requirements/guidelines to perform the surface preparation,
cleaning and painting work of Structural steel, Storage Tanks, Piping, Cable Tray Touch-up and
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REV NO.: 00
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Page 229 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
Instrumentation Support. The extent of the procedure shall be as per project specification, manufacturer’s
work instruction/procedure and applicable code/paint data sheet.
2.0 PURPOSE
The purpose of this procedure is to provides the information, method and control for surface preparation,
cleaning, painting and touch –up / repair on damage portion work at fabrication as well as erection site.
3.0 AREA OF APPLICATION
This procedure is applicable for conducting the surface preparation, cleaning & painting work of Structural
steel, Storage Tanks, Piping, Cable Tray Touch-up and Instrumentation Support for ASFD Cobalt Dryer Project.
4.0 REFERENCES
Manufacturer’s work instruction/ Paint data sheet
Approved Inspection & Test Plan
Project Specification
Safety Data Sheet
5.0 Paint Storage
All Paint materials will be stored in accordance with the manufacturer’s recommendation and in
compliance to the project requirement and specifications in this regard.
All Paint materials will be stored in enclosed / protected and well-ventilated areas and manufacturer’s
recommendation pertaining to the storage will be complied with.
Integrity of original containers will always be ensured.
Paints will be issued from stores on “First come first issue basis.”
6.0 General Requirement
All tools, spray gun, brushes, base material, hand power tools for cleaning and all equipment,
scaffolding materials, shot/sand blasting equipment and air compressor, proper cover shed for
protection of job from wind , rain , sun etc., required to be used shall be suitable for work and all in
good condition.
Adequate protection for surrounding areas and adjacent materials need to be taken care to avoid
spotting, over spray or contamination produced by these operations.
Equipment shall be protected and masked before surface preparation and painting if any.
Surface temperature and relative humidity shall be followed as per manufacturer’s recommendation
during the application of paint.
Substrate/painting area shall be protected from foreign materials like oil, grease, dust particles, flame
etc.
For proper system, surface preparation & painting register/ log sheet shall be maintained and duly
monitored by QA/QC engineer regularly.
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 230 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
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Air used for blasting must be clean, oil free & dry; moistures & oil separator have to be ensuring the
same.
DFT & WFT measuring instrument, Hygrometer and measuring jug etc, shall be used for inspection
purpose and for proper painting application.
7.0 Preparation of Surface for Painting
Mill scale, rust scale, foreign matter and all other contaminants like oil, grease etc., shall be removed
fully to ensure that a clean and dry surface is obtained.
Blast cleaning shall not be performed when weather having humidity exceeds 85 %.
Abrasive like grit, shot or copper slag of approved quality should be used.
Use wire brush and pig hammer is to be done whenever shot blasting is not possible due to lack of
access. Remove the dust and debris by brush or vacuum.
Any wet surface shall be dried before painting and after shot blasting immediate painting to be done.
Welding areas shall not be painted until the completion of welding operation. However Welding has to
be carried out after erection at site, the shop coat of paint shall be removed thoroughly before welding
and the adjoining steel surface including welding area shall be repainted after proper cleaning. After
joint cleaning, stripe coating to be applied first then scheme to apply for intermediate and final coat.
Solvent and high pressure wash prior to blasting is required to remove all mill, oil and grease.
The compressed air for blasting shall be free from oil & water.
Dry abrasive blast cleaning shall be in accordance with SANS 10064 to a class SA 2.5 with a blast profile
of 50-100 micron.
Final cleaning shall be done by compressed air or vacuum cleaning to remove blast products and
dust.
The prime coat shall be applied within four hours of completion of the surface preparation.
8.0 ADHESION TEST
After given curing time, the area of interest for the checking of adhesion test. It should be free from dust &
oil. Make a x cut with the short edge tool above the area of interest and maintain the angle between the x is
15 degree to 30 degree. Then affix one inch adhesion tape over the cut and peel off the same immediately. If
the paint stuck the adhesion tape, it is recommended to re-blast the area and repaint the primer.
9.0 ENVIRONMENTAL CONDITION
Humidity: Substrate temperature must be at least 3 °C above the dew point and relative humidity less
than 85 %.
Environment Temperature: Application temperature shall be maintained between 5°C to 30°C. Steel
surface temperature shall be controlled between 5°C to 30°C.
Proper ventilation and lighting shall be ensuring at the application area.
Application of painting in dusty environment shall be avoided.
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10.0 PAINTING APPLICATION
The paint shall not be applied in damp weather or in dusty conditions and when temperature is
below 5 degree Celsius.
Paint shall not apply when humidity is above 85% or during fog, mist or rain.
Paint shall not apply when temperature falls below 10 degree centigrade. Paint shall not be applied
to steel at a temperature above 50 degrees Celsius.
When steel is painted in hot weather, precautions shall be taken to ensure that the specified
Thickness of paint is obtained.
All the primers and intermediate coats are applied with airless spray and finishes applied with brushing
consistency. Thinner should be added only if the viscosity increases due to Temperature change during
application. Normally addition of thinner is restricted up to 5 10% by volume in case of brush
application. In case of spray application, only recommended thinner shall be uses to bring the paints to
spraying consistency.
Best cleaned surfaces shall be coated with primer within maximum 3-4 hours. If relative Humidity is
over 75% this should be reduced to 1-2 hours for better performance.
Application of paint is recommended at ambient temperature. The substrate should be at ambient
temperature.
Dry film thickness control: Measurement shall be carried out as per the SSPC-PA 2.
All work shall be free from paint runs, sags, blisters or other defects. All surfaces with paint stains and
splash or spray marks shall be removed and surface restored which is acceptable to the QA/QC
Engineer.
11.0 PAINTING DATA
SECTION /
SR. TOTAL DFT
EQUIPMENT SPECIFICATION OF PAINT
NO. (MICRON)
DESCRIPTION
•System: K
•Surface Preparation: Type 1, Abrasive Blasting Cleaning
Paint for Cobalt
•Primer: Cross Linked Epoxy Primer (Carboguard 880), DFT 60-90 microns
area- Feeding
•Intermediate: High Build Phenolic Epoxy (Carboguard 920-S), DFT 180-220 microns
1. section- 420-530
•Final: High Build Phenolic Epoxy (Carboguard 920-S), DFT 180-220 microns
Conveyors steel
•Colour: MID SEA GREY
structural
•SANS STD: 10140-2
•Code: G24
2. Paint for Cobalt •System: C2 340-460
area- Feeding •Surface Preparation: Type 1, Abrasive Blasting Cleaning
section- •Primer: Epoxy Polyamide Primer (Carboguard 880) DFT 60-90 microns
Conveyors for •Intermediate: High Solid (Cross Linked Novolac Epoxy / Phenoline 921 or similar
Hand railing approved), DFT 180- 220 microns
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•Final: High Solid (Phenoline 305), DFT 100-150 Microns
tubing, posts,
•Colour: Golden Yellow
kick plates and
•SANS STD: 10140-2
Guard covers
•Code: B49
•System: A
•Surface Preparation: Type 1, Abrasive Blasting Cleaning
•Primer: Epoxy Polyamide Primer (Carboguard 880) DFT 60-90 microns
Paint for Diesel
•Intermediate: N/A
3. Tanks- 235-290
•Final: High Build Epoxy (Carboguard 890) DFT 175-200 microns
Externals
•Colour: MID SEA GREY
•SANS STD: 10140-2
•Code: G24
•System: K
•Surface Preparation: Type 1, Abrasive Blasting Cleaning
•Primer: Cross Linked Epoxy Primer (Carboguard 880), DFT 60-90 microns
Paint for Diesel
•Intermediate: High Build Phenolic Epoxy (CARBOGUARD 920-S), DFT 180-220 microns
4. storage tank- 420-530
•Final: High Build Phenolic Epoxy (Carboguard 920-S), DFT 180-220 microns
80kl staircase
•Colour: MID SEA GREY
•SANS STD: 10140-2
•Code: G24
•System: C2
•Surface Preparation: Type 1, Abrasive Blasting Cleaning
Paint for Diesel
•Primer: Epoxy Polyamide Primer (Carboguard 880) DFT 60-90 microns
storage tank-
•Intermediate: High Solid (Cross Linked Novolac Epoxy / Phenoline 921 or similar
80kl for Hand
5. approved) DFT 180-220 microns 340-460
railing tubing,
•Final: High Solid (Phenoline 305), DFT 100-150Microns
posts and kick
•Colour: Golden Yellow
plates
•SANS STD: 10140-2
•Code: B49
•System: C
•Surface Preparation: Type 1, Abrasive Blasting Cleaning
•Primer: Epoxy Polyamide Primer (Carboguard 880) DFT 60-90 microns
Paint for Diesel
•Intermediate: High Solids (Cross Linked Novolac Epoxy / Phenoline 921 or similar
Piping
6. approved), DFT 180- 220 microns 340-460
Externals, MOC:
•Final: High Solid (Phenoline 305), DFT 100-150 Microns
CS
•Colour: MID SEA GREY
•SANS STD: 10140-2
•Code: G24
7. Paint for •System: C 340-460
Compressed Air •Surface Preparation: Type 1, Abrasive Blasting Cleaning
Piping, •Primer: Epoxy Polyamide Primer (Carboguard 880) DFT 60-90 microns
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•Intermediate: High Solids (Cross Linked Novolac Epoxy / Phenoline 921 or similar
approved), DFT 180 -220 microns
Externals, MOC: •Final: High Solid (Phenoline 305), DFT 100-150 Microns
CS •Colour: MID SEA GREY
•SANS STD: 10140-2
•Code: G24
•System: C
•Surface Preparation: Type 1, Abrasive BlastingCleaning
Paint for Gland •Primer: Epoxy Polyamide Primer (Carboguard 880)DFT 60-90 microns.
seal water •Intermediate: High Solids (Cross Linked Novolac Epoxy / Phenoline 921 or similar
8. piping, approved), DFT 180-220 microns 340-460
Externals, MOC: •Final: High Solid (Phenoline 305), DFT 100-150 Microns
CS •Colour: MID SEA GREY
•SANS STD: 10140-2
•Code: G24
•System: C
•Surface Preparation: Type 1, Abrasive Blasting Cleaning
•Primer: Epoxy Polyamide Primer (Carboguard 880) DFT 60-90 microns
Paint for Piping •Intermediate: High Solids (Cross Linked Novolac Epoxy / Phenoline 921 or similar
9. indication, approved), DFT 180- 220 microns 340-460
MOC: CS •Final: High Solid (Phenoline 305), DFT 100-150 Microns
•Colour: Mid Flag green
•SANS STD: 10140-2
•Code: E08
•System: H
Paint for Cable
10. •Colour: Galvanized
tray touch up
•Refer SANS 121 for required galvanized specifications
•System: K
•Surface Preparation: Type 1, Abrasive Blasting Cleaning
Paint for
•Primer: Cross Linked Epoxy Primer (Carboguard 880), DFT 60-90 microns
11. Instrumentatio 420-530
•Intermediate: High Build Phenolic Epoxy (Carboguard 920-S), DFT 180-220 microns
n support
•Final: High Build Phenolic Epoxy (Carboguard 920-S), DFT 180-220 microns
•Colour: Light- Medium Grey
12.0 STRIPE COAT
A coating system may consist of a coat of an anticorrosive material (primer) and one or more stripe coats.
Stripe coats are applications of the top-coat (paint) which has been applied to edges of structure, welds,
drain holes and other areas to over-come potential problems that can result when paint coverage is
difficult/insufficient or non-uniform.
Stripe coat is generally applied with combination of airless spray & brush application method to get specific
DFT.
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13.0 TOUCH-UP AND REPAIR
The surface must be dry and no rust during finishing secondary surface preparation and prior to apply paint.
Mark out the repair and manual cleaning shall be done before the application of paint.
All welding seams must have a surface finish that ensures the quality of paint system shall be maintained in
all respects. Holes in welding seam, undercuts, cracks, etc. are not permitted. If found, they must be
remedied by welding or grinding.
All sharp edges, weld spatters etc. shall be removed or rounded off before sand blasting.
14.0 REPAIR PROCEDURE
Repairs of major/minor areas when the primer paint is damaged
A major should be dealt with as if the project were beginning. The recommendations given earlier for
steel preparation, coating application etc., MUST all be adhered to. The original complete scheme
should be applied. This is specific when the primer is damaged.
Repairs when primer is intact & the second coat is damaged
Under this heading are repairs to areas damaged either at the initial coating stage or caused during
service, mechanical damages, handing damages etc. The principle requirements are:
i) Remove any corrosion by means of either vacuum blasting or hand tools like disc sander and
grinder.
ii) Abrade area immediately surrounding repair to provide key for subsequent paint application.
iii) If small areas are involved and application is by brush, several coats may be required to achieve the
correct dry film thickness. If the area is large then airless/air spray has to be employed. A full recoat
would be required to maintain.
Repair when primer and second coat is intact but third coat is damaged
Under this heading areas to areas damaged either at the initial coating stage or caused during service,
mechanical damages, handling damages etc. the principle requirements are:
i) The area to be repaired must be fresh water washed and dry.
ii) Remove any corrosion by means of either vacuum blasting or by hand tools.
Note: In all above cases, DFT shall be checked for compliance.
15.0 SAFETY
All work carried out on the site must comply with good safe working practice and the specific Conditions
of a permit to work where issued an operational site.
Safe working areas: proper use and erection of scaffolding, ladder etc.
Safety requirement associated with abrasive blast cleaning.
Identification of coating materials-with references to any associated hazards such as toxicity,
Flammability etc.
Read safety caution on the label of paint tins before applying any coat.
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Safety equipment’s shall be used to avoid direct contact with skin and body parts. Painting shall be
carried out in good ventilated area only.
16.0 INSPECTION
Inspection of supplied paints, in-process inspection and final inspection shall be carried out as
Per approved inspection and test plan, project specification and Manufacturer's work
instruction/recommendations. Approved format for documentation should be followed throughout the
project.
17.0 DOCUMENTATION & RECORD
The following documents shall be maintained at site
Manufacturer’s data sheet
Batch test certificates
Calibration certificate of instruments
Inspection Reports
Records :
Reference Documents :
ITP Reference No :
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WELDING PROCEDURE QUALIFICATION &
SCHEDULE
SR. EFFECTIVE REV. MSS MANAGER MSS PROJECT CLIENT
CLIENT QA/QC
NO. DATE NO. QA/QC MANAGER SUPERVISOR
TABLE OF CONTENTS
SR.NO DESCRIPTION
1.0 PURPOSE
2.0 SCOPE
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3.0 REFERENCES
4.0 DEFINITIONS / ABBREVIATIONS
5.0 PROCEDURES
WPS PREPARATION
STEP INCONDUCTING WPQT
RE-TEST
6.0 SPECIAL REQUIREMENTS
7.0 RECORDS
APPENDICES
APPENDIX I - WELDING PROCEDURE SPECIFICATION
APPENDIX II - PROCEDURE QUALIFICATION RECORD
1.0. PURPOSE
The purpose of this procedure is to provide guidelines for qualifying WPS required in the steel fabrication
works.
2.0. SCOPE
This procedure shall be applied for welding procedure qualification test on all WPSs
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established in the fabrication of structure, process pipe-works, pressure vessels and
related works.
3.0. REFERENCE
AWS D1.1, 2006 : Structural Welding Code
ASME IX 2007 : Steel Welding and Brazing Qualification
API 1104, 2005 : Welding of Pipeline and related Facilities.
BS EN 288-3 :1992(Part 3) Welding Procedure test for Arc Welding of Steel.
4.0. DEFINITION /ABBREVIATION
WPS - Welding Procedure Specification.
WPQT - Welding Procedure Qualification Test.
PQR - Procedure Qualification Record.
WQT - Welder Qualification Test.
5.0. PROCEDURES
5.1. WPS preparation
5.1.1. KI’s Welding Engineer shall identify and submit to CLIENT the list of relevant WPS to be used for the
project from the pre-accepted WPS. If additional WPS is required. WPS shall be developed and submitted
for Client’s approval before WPQT.
5.1.2. The Welding Engineer shall formulate the welding procedures to the joint configuration and application.
The WPS shall be prepared as per AWS D1.1 for structural and ASME IX for piping or other code
requirements. (See appendix I for the WPS format).
5.1.3. The proposed WPS shall contain all the essential welding parameters whichever are applicable as per
appendix I.
5.1.4. Upon approval of the WPS, a WPQT shall be carried out in the presence of CLIENT Representative.
CLIENT Representative shall be informed 48 hrs in advance prior to the testing.
5.2. Step in Conducting WPQT
5.2.1. Prior to commencement of WPQT, the following shall be verified by CLIENT’s representative and KIs
welding engineer.
a) Test material (s) used, including the heat number.
b) Dimensions of the test material (s) e.g. length, diameter, thickness etc.
c) Edge preparation of the test material (s).
d) Adequacy of lighting for cleaning and visual inspection.
e) Current i.e. amperage and voltage by mean of AC/DC Digital Clamp Meter (tong tester).
f) Setting of current type, polarity including amperage and voltage.
g) Correctness of welding consumables to be used as per proposed WPS.
5.2.2. Upon fit-up, weld preparation and alignment shall be checked for compliance to the proposed WPS.
After fit-up inspection, mark the PQR number, test position and indicate the top of joint position (if pipe
is used for the test).
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5.2.3. The test piece shall be secured firmly per the required test position. Preheat the test piece properly by
gas burners or other approved method to the required temperature specified in the proposed WPS.
Check the preheat temperature with thermo sticks or equivalent before allowing the welder to
commence welding. The required preheat shall be achieved uniformly across the thickness of the test
piece.
5.2.4. A trial test may be carried out on a separate specimen prior to welding on the test piece to ensure the
welding parameters set out in the WPS are maintained.
5.2.5. Monitor and record the following welding parameters in the PQR form (see appendix II) on each pass
until completion of test weld to ensure compliance within the ranges specified in the proposed WPS.
a) Travel speed, wire feed speed current i.e. Amperage and voltage by mean of AC/DC Digital Clamp
meter (tong tester).
b) Type of Shielding Gas, Purging Gas & flow rate.
c) Direction of travel for vertical welding
d) Use of specified welding consumables diameter, electrode stick out length.
e) Welding technique i.e. string, weave, split layer.
f) Interpass temperature by use of or Thermosticks digital thermometer.
g) Approximate width of weld pass.
h) Approximate thickness of weld layer.
i) Interpass cleaning method.
j) Sequence and number of weld passes per layer.
k) Treatment to back side (back gouged, ground, back welded, inspection etc.).
5.2.6. Upon completion of welding, visual inspection shall be carried out in accordance with applicable CODE &
Spec.
5.2.7. Upon verification and acceptance of the recorded welding parameters in the PQR form followed by visual
acceptance of test weld, the KI’s weldingengineer shall arrange for the required NDT in accordance with
codes and client’s specification.
5.2.8. NDT result shall be verified by Client’s Representative prior to any further testing. For acceptable test
weld, it shall be subjected to destructive testing.
5.2.9. KI’s Welding Engineer shall proceed to illustrate the locations of test specimens on the welded test piece
for each type of destructive test before cutting at site or direct dispatch to aft approved independent
testing laboratory for both cutting and machining work. The location for removal of the required
specimen shall be in accordance with Code/ Client Spec.
5.2.10. The entire required test carried out in the laboratory shall be witnessed by the KI’s Representative and
Client’s Representative.
5.2.11. The following shall be checked during the course of mechanical testing:
a) Identification markings on the specimen to its related PQR number, type of test and number of
specimens required.
b) Dimensions of tensile, bend, impact test specimens.
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c)Calibration certificates of tensile test and impact test equipment are valid, dimensions of guided bend
test equipment must be adequate to produce bending radius specified by test code for root, face and
side bend testing.
d) Impact testing is carried out at the specified temperature.
e) Specified numbers of hardness spots are taken on the regions of the macro etched test specimen i.e.
weld heat affected zone, weld area and base metal.
5.2.12. During each test all results shall be recorded on the draft copies of test report by the laboratory tester.
5.2.13. Upon completion, test results shall be signed off and a copy extended to the KI’s representative and client’s
representative for signature and evaluation against the test code and specification.
5.2.14. Upon acceptance of the mechanical test results, the WPS/PQR shall be prepared by the KI’s welding
engineer using the format shown in appendix I and II. The WPS/PQR shall be submitted to CLIENT for review
and approval.
5.3. Retest
5.3.1. When Retest is not allowed
Unacceptable defects evaluated by visual; NDT and macro etch testing shall be cause for rejection. A new test weld
shall be required.
5.3.2. When retest is allowed
When one of the following mechanical test specimens fails to meet the required acceptance criteria, two
additional specimens shall be prepared for retesting. The location of the two additional specimens shall reflect the
location of the failed specimen. If one or both of the retest specimens fail, then this shall he cause for rejection. A
new weld shall be required
Tensile test.
Bend test.
Impact test (when applicable).
Hardness test.
Prior to retest, a study and evaluation shall be made on the failed test to established probable cause of failure.
6.0. SPECIAL REQUIREMENTS
6.1. KI’s welding engineer shall prepare the WPSs to simulate, the actual welding conditions and materials to
be used for production welding. Limitations imposed by the essential variables of the procedure
qualification shall be adhered to in production welding.
6.2. Only skilled and experienced welders shall be assigned for WPQT to minimize
rework.
7.0. Records
All records pertaining to welding qualification test shall be kept by the KI’s Welding Engineer. All copies of the
approved WPS shall be readily available for reference by the Welders, Welding Engineers and Client’s
Representative.
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 241 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
APPENDICES
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 242 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
WELDING PROCEDURE SPECIFICATION
WPS NO. REV. NO. REV. DATE CODE SHT 1OF 2 PROCESS TYPE :
MANUAL - SEMI-AUTO - MACHINE - AUTO - WELD GROOVE.- SINGLE
VEE - DOUBLE VEE - SINGLE BEVEL DOUBLE BEVEL -
SINGLE U - DOUBLE U - SINGLE J DOUBLE J - COMB.
ANGLE GROOVE - GROOVE ANGLE < 30 T’K&Y -
FILLET WELDS : SINGLE PASS - I¥IULTI-PASS
SUPPORTING PQR NO .° (1) (2) (3) (4)
MATERIAL GROUPING .° ASME : P.NO .° GROUP NO. TO P. NO. GROUP NO.
PTS TYPE NO. : TO
AWS .° GROUP NO .° - TO
TUNGSTEN ELECTRODE SIZE .° TYPE : - SHIELDING .°
YES - NO - GAS - MIX % - FLOW - LPM
PURGING : YES - NO - GAS - MIX % - FLOW - LPM
TRAILING GAS : YES - NO - GAS - MIX % - MIX % - LPM
FILLER METAL SPECIFICATION :
( Root ) MFG I BRAND
( F/C ) MFG / BRAND
FILLER METAL CLASSIFICATION .-
( Root ) A NO. - F NO.
( F/C ) A NO. - F NO. -
FLUX / WIRE CLASSIFICATION : FLUX BRAND WELDING CURRENT ( Root )
DC - AC POSITIVE - NEGATIVE PULSED AND POLARITY ( F/C )
DC - AC POSITIVE - NEGATIVE PULSED ( ) DC
AC POSITIVE NEGATIVE PULSED
WELD FEED SPEED RANGE,MM I MIN : SAW FCAW GMAW MODE OF METAL
TRANSFER FOR GMAW SHORT CIRCUIT GLOBULAR: SPRAY: SUPPLEMENTAL FILLER
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 243 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
METAL : POWDERED .- GRANULAR : WIRE :
SINGLE OR MULTIPLE ( Root ) S - M - STRING - WEAVE - SPLIT LAYER -
PASS USING STRING ( F/C ) S - I\/I - STRING - WEAVE - SPLIT LAYER -
WEAVE OR SPLIT LAYER : ( ) S - M - STRING - WEAVE - SPLIT LAYER WELD WIDTH
MAXIMUM : MM ( ) - ( ) ( ) - VERTICAL PROGRESSION : ( )
UP - DOWN ( ) UP DOWN
POSITION OF PRODUCTION WELD : SMAW - GMAW FCAW GTA¥\ SAW
NUMBER OF ARCS : ELEC. SPACING LONGITUDINAL °. LATERAL : ANGLE : TRAVEL DIRECTION :
ROOT WELD BACKING : NO - YES BACKING MAT'L
STICK-OUT LENGTH : ORIFICE / CUP SIZE : CONTACT TUBE TO WORK DISTANCE :(mm)
MAX. NO. OF HEAT CYCLES : TWO (2) MAX. TIME BETWEEN HEAT CYCLES : 2 DAYS
TREATMENT OF BACKSIDE OF ROOT WELD : NONE - GRIND GOUGE OTHERS
PREHEAT / INTERPASS TEMPERATURE : MINIMUM : MAXIMUM : METHOD OF
PREHEATING : GAS TORCH METHOD OF TEMP. CHECK : TEMPERATURE CRAYON / DIGITAL THERMOMETER POST WELD
HEAT TREAT REQUIRED : NO - YES - TEMP : - HOLDING TIME : -
CHARPY IMPACT TESTING REQUIRED: NO - YES - REPORT NO. : HARDNESS TESTING
REQUIRED : NO - YES - REPORT NO. : TENSILE TEST : NO - YES - REPORT NO. .°
BEND TEST : NO - YES - REPORT NO. :
MACROETCH & PHOTO : NO - YES - REPORT NO. :
OTHERS : NO - YES - REPORT NO. :
RANGE OF WELD METAL THICKNESS : RANGE OF BASEMETAL THICKNESS WHEN PRODUCTION ( ›
uAX. WELD NOTCH TOUGHNESS IS :
( ) MAX. REQ’D NOT REQ’D
MIN : MIN :
RANGE OF NOM. PIPE DIAMETERS :
MIN MAX MAX : MAX :
WELDING PROCEDURE SPECIFICATION
WPS NO.: REV.NO: REV. DATE: SHT. 2 OF 2
SPECIFIED PRODUCTION WELDING PARAMETERS
INTER PASS TEMP.
FILLER DIAMETER
VOLTAGE RANGE
RANGE MM/MIN
CLASSIFICATION
CURRENT TYPE
RANGE KJ/MM
AND POLARITY
FILLER MATEL
RAVEL SPEED
PASS / WELD
HEAT INPUT
SPLIT LAYER
AMPERAGE
DEG.C MAX
WELDING
PROCESS
WEAVE
STRING
RANGE
LAYER
(MM)
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 244 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
JOINT PREPARATION SKETCH
JOINT DETAILS BEAD SEQUENCE
NOTE:
1) All dimension in mm
2) Material type:
CONTRACTOR: DATE :
CLIENT : DATE :
PQR NO. FOR WPS N6. DATE :
TEST WELD DETAILS
JOINT DETAILS BEAD SEQUENCE
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FORMATE ID:
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DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 245 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
TEST POSITION : MIN. HEAT .
TEST MATERIAL TYPE : °c
SECT. 1 . SECT.2 :
MAX.INTERPASS TEMP.: ’C
HEAT NOS.:
TEST MATERIAL THK. PLATE : PIPE: PWHT .° YES NO
NOM.TEST PIPE DIA :
NDT :
ROOT WELD BACKING : YES NO
RT UT MPI Pl N/A
BACKING MATERIAL :
IMPACT TESTS : YES NO
MAX. WELD WEAVE WIDTH :
HARDNESS SURVEY : YES NO
MANUAL : OTHER:
MACROTCH + PHOTO : YES NO
GAS PURGE : TYPE FLOW LPM TENSILE/BEND TEST : YES NO
GAS SHIELD : TYPE FLOW LPM OTHERS . YES NO
BACKING GAS : TYPE FLOW LPM Welder Name
Welder No.
CLASIFICATION
AND POLARITY
TRAVEL SPEED
PROGRESSION
FILLER MATEL
CURENT TYPE
WEAVE WIDT
TEMP.DEC.C
SPLIT LAVER
HEAT INPUT
INTER PASS
AMPERAGE
LAYER NO.
DIAMETER
FILLER
MAX.MM
MM/MIN
PASS NO.
VOLTAGE
PROCESS
VETICAL
STRING
WEAVE
KJ/MM
MATEL
(MM)
WELDIND SCHEDULE
PLT THICK N0MINAL WELD WELD
SL.NO STRUCTURAL MEMBER WELD TYPE
t1 t2 LEG SIZE THR SIZE LENGTH SPACING
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 246 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
1 BTM TO BTM PLATING 7 7 BUTT
2 SHELL TO SHELL PLATING 6 6 BUTT
3 SHELL TO DECK PLATING 6 6 DC 5 3.5
4 DECK TO DECK PLATING 6 6 BUTT
5 TRANS & LONGI BHD TO BTM PLT 6 7 DC 5 3.5
6 TRANS BHD TO SHELL PLT 6 6 DC 5 3.5
7 TRANS & LONGI BHD TO DECK PLT 6 6 DC 5 3.5
8 BHD TO BHD PLATING 6 6 BUTT
9 TANK TOP : PLATING TO PLATING 6 6 BUTT
10 TANK TOP PLT TO LON/TRAN BHD 6 6 DC 5 3.5
11 FLOORS TO BTM PLATING 6 7 SI 5 3.5 65 250
12 MARGIN PLT TO BTM/SHELL PLT 6 7 DC 5 3.5
13 FLOORS WEB TO FACE 7 8 SI 5 3.5 65 250
14 C.L/SIDE GIRDER TO BTM PLT
(1) OUT SIDE E.R 6 7 DC 5 3.5
(2) INSIDE E.R 6 7 SI 5 3.5 65 150
15 C.L/SIDE GIRDER TO TANKTOP PLT 6 6 DC 5 3.5
16 C.L GIRDER : WEB TO FACE 7 8 SI 5 3.5 65 150
17 SIDE GIRDER : WEB TO FACE 6 7 SI 5 3.5 65 250
18 TANK TOP WEB TO PLATING 6 6 DC 5 3.5
19 TANK TOP WEB TO FACE 6 7 DC 5 3.5
20 LONGITUDINAL TO :
( a ) BTM PLATING 6 7 SI 5 3.5 65 250
( b ) TANK TOP PLATING 6 6 SI 5 3.5 65 250
( c ) SHELL PLATING 6 6 SI 5 3.5 65 250
( d ) LONGI BHK PLATING 6 6 SI 5 3.5 65 250
( e ) DECK PLATING 6 6 SI 5 3.5 65 250
(f) TRANS BHD PLATING 6 6 SI 5 3.5 65 250
21 WEB FRAMES TO:
( a )SHELL PLATING 7 6 SI 5 3.5 65 200
( b )LONGI/TRANS BHD PLT 7 6 SI 5 3.5 65 200
( c )DECK PLATING 7 6 SI 5 3.5 65 200
22 GIRDER/STRINGER WEBS TO:
( a )LONGI BHD PLATING 7 6 SI 5 3.5 65 250
( b ) TRNAS BHD PLATING 7 6 SI 5 3.5 65 250
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 247 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
( c )DECK PLATING 7 5 SI 5 3.5 65 250
23 GIRDER /STRINGER WEB TO FACE 7 8 SI 5 3.5 65 250
24 DECK TRANS TO DECK PLATING 6 5 SI 5 3.5 65 250
25 BKTS TO BHD/SHELL/DECK PLT 6 6 DC 5 3.5
26 BKTS TO:
a) WEB FRAMES 6 6 DC 5 3.5
b)STRINGER 8 8 DC 5 3.5
27 ENGINE GIRDER TO BTM PLT 12 7 DC 5 3.5
28 ENGINE GIR. WEB TO RIDER PLT 12 22 FULL PEN
29 BULKWARD PLATING TO SHELL 6 6 BUTT
30 BULKWARD STAY TO DECK 6 6 DC 5 3.5
31 DECK HOUSE BHDS TO:
a) MAIN DECK 5 6 DC 5 3.5
b)DECK HOUSE TOP 5 4 DC 5 3.5
32 DK HOU LONG BHD TO TRAN BHD 5 5 DC 5 3.5
33 DK HOU LONG BHD TO BHD PLATING 5 5 BUTT
34 DK HOUSE STIFFENER TO:
35 a) DECK PLATING 6 5 SI 5 3.5 40 300
b)SHELL/BHD PLATING 6 5 SI 5 3.5 40 300
NOTE:-
DC : DOUBLE CONTINOUS
SI : STAGGERED INTERMITTENT
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 248 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
METHOD STATEMENT
FOR
WATERPROOFING WORK
SR. EFFECTIVE REV. MSS MANAGER MSS PROJECT CLIENT
CLIENT QA/QC
NO. DATE NO. QA/QC MANAGER SUPERVISOR
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 249 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
WATERPROOFING WORK
General:
Raw Materials used in Waterproofing & its Acceptance Criteria
Cement:
Cement shall be 43 / 53 grade OPC (Fly ash shall be used with OPC) / PPC and not more than 8 weeks old
and it shall be free of lumps.
Natural sand:
Silt content of natural sand shall not exceed 12% by volume for 1 Hr and 8% by volume for 2Hrs.
Percentage passing 600 micron shall be more than 45%.
Fly ash:
1) Sources of fly ash must be standardized as per test reports and fly ash must meet the requirements of
IS 3812. Further retention on 45 micron sieve after wet sieving should be less than 20%.
2) Fly ash should be free from lumps.
Bricks:
Bricks from which brick-bats are made shall not be under burnt and percentage of over burnt bricks shall
not be greater than 10%. Bricks used for brick bats shall be either be full bricks or 3/4th bricks. Bricks
shall be broken at site with the help of mallet. Irregular broken pieces of bricks shall not be used.
Water:
Sulphate and Chlorides content in the water shall be within specified limits as specified in IS-456:2000.
Water proofing compound:
A water proofing compound of reputed manufacturer shall be used. Care shall be taken to see that it is
compatible with the type / brand of cement being used. Packing shall clearly bear date of
manufacturing, lot number, date of expiry, usage guidelines etc.
Glazed tile pieces (for China Mosaic Type Waterproofing):
Broken pieces of selected white / coloured glazed tile pieces of size 25mm to 50mm and 6mm thick or as
specified on drawing.
Bonding Agent:
Suitable bonding agent from the reputed manufacturer shall be used.
Rough Shahabad stones or equivalent stones from quarry:
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 250 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
Rough Shahabad Stone slabs shall be of uniform size and shall be free from cracks and fissures.
Basic Types of waterproofing
Waterproofing of Toilets
Waterproofing of Terraces
Box type waterproofing for underground tanks
Procedures for Waterproofing of Toilets:
Pre Waterproofing Procedures:
1) It shall be ensured that toilet plumbing lines are installed in masonry and chases are rendered with
non-shrink grout prior to cleaning activity of sunk is undertaken.
2) Cleaning of sunk slab base and sides of beams shall be carried out as regards all those materials,
mortar, oil, grease etc. thoroughly by wire brush and the area shall be washed clean and surface should
be wet.
3) Injection grouting at all major honeycombed portions shall be carried out, if necessary, after physical
observation of the sunk.
4) Sunk slab shall be cured for at least 2 days by ponding, to test for leakages and to serve water hungry
concrete surface.
5) In case of major leakage, gravity grouting or pressure grouting shall be resorted to, to stop leakages.
6) Holes for PVC and other outlet pipes shall be marked clearly for size and locations. Outer surface of
PVC pipes shall be roughened for better bonding. Diameter of hole shall not exceed pipe diameter.
7) Levels of water-proofing shall be clearly marked on the toilet walls with slope towards outlet, as
specified in drawing or minimum 1:100 otherwise.
During Waterproofing Procedures:
1) Application of chemical waterproofing coat (crystalline / elastomeric / polymer) can be done, if
required to entire sunk portion before base coat.
2) Base coat using cement mortar in proportion 1:4 or as specified by QA Department with approved
waterproofing compound shall be applied over top of base slab of sunk. Maximum thickness of base
coat shall be 25 mm at upper end of slope.
3) Proper slope shall be given to base coat as per drawing towards drain spout and drain spout to be
fitted simultaneously with the base coat, as an additional precaution to take care of seepage, if any.
Base coat shall also be applied to the sides of the toilet sunk up to one foot above the finished floor level
(F.F.L) of the adjacent floor.
3) Drain spout shall be 20 mm / 25mm diameter GI / UPVC, fixed so as to project at least 4” beyond wall
surface. Drain spout mouth shall be cut to the shape of half nozzle by cutting at 30º angle to facilitate
water dropping in the form of a projectile. Holes for drain pipes should be done before starting any type
of waterproofing.
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 251 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
4) Drain pipe mouth shall be fitted with PVC grating or filter media form inside and chicken mesh / wire
mesh
from outside.
5) Curing of base coat shall be done by ponding for 3 days and checked against leakage. Leakage, if
observed, shall be rendered with reapplication of base coat to ensure no leakage.
6) Floor traps and other plumbing lines shall be installed in brick masonry after application of base coat.
7) Slope of 1:100 shall be provided for toilet piping and water proofing. Floor trap shall be fixed with
respect to finished floor level (F.F.L) of the toilet.
8) Rendering of holes shall be done using compatible bonding agents; SBR based expansive grouts,
waterproofing compounds and M15 grade concrete.
9) All internal drain lines shall be erected as per layout given on the drawing and shall be pressure
tested.
10) Application of brick bat coba shall be started, once plumbing lines are satisfactory pressure tested.
11) Bricks selected for using as Brick Bat Coba shall be either full brick or 3/4th brick made out of one
complete brick by breaking into required size, using mallets.
12) Brick bat shall not be stored in the form of a heap at one place and soaked thoroughly for about 15
minutes prior to their placing.
13) Use of plasticizer in mortars is recommended to increase workability. Mortar mixed shall be used
within 1 Hour of preparation.
14) Pre-soaked brick-bats shall then be laid in straight / radial, by inserting brickbats to a depth of about
15mm by light tamping with the help of mallets. Thickness between adjacent layers of brickbats shall
not exceed 25mm.
15) Application of brick-bats shall proceed from one corner and shall be laid in radial pattern / straight
pattern to drain of any water which has seeped through. Thiyya (level pads)s (level pads) for the same
shall be given by Site Engineer, considering into account adequate slope.
16) Edge rounding shall be done simultaneously at corners. (Junction of slab & wall)
17) The brickbat Layer shall then be cured for minimum 3 days by ponding
18) After curing is over, the surface shall be applied with a finishing coat of cement sand mortar in the
proportion 1:3 with water-proofing compound till top of brick-bats.
19) Top coat shall be of neat cement slurry of adequate consistency and shall be monolithic with brick-
bats.
20) Finished surface shall then be cured for at least 7 days by ponding and then tested for leakages, if
any.
Post Waterproofing Procedures:
Date of finishing shall be marked on the surface for curing by ponding for about 7 days.
NOTES:
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 252 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
Water-proofing once done, shall not be broken or pierced. If water proofing is to be punctured, due
care shall be taken to limit the damage to the restricted area. The cracks due to hammering shall not
spread over the large area.
Repairing of the punctured area shall be done by using bonding agent and expansive grouts.
For precise waterproofing works, the following procedure can also be used depending upon the
requirement of the project.
First Coat (Base Coat) of Water Proofing:
1) Over RCC surface, crystalline waterproofing or chemical treatment must be required to apply. Apply
this coat on floor and walls about 1’ above finished floor level (F.F.L) and also outside toilet door outer
frame face of entrance of toilet.
OR
1) Apply waterproofing coat with admixture and cement in the ratio as specified by manufacturer by
weight applied on R.C.C surface in two coats, duration between first and second coat shall be min 4 hrs
and max 24 hrs.
2) First coat chat of 1:4 waterproofing plaster with waterproofing admixture to be applied over the
above coat.
3) Second coat of water proofing “seal roof” shall be layer of plaster 15 mm thick in which metal of 15 to
20 mm nominal size will be embedded / fixed by hand at random with mortar mixed in proportion 1: 3.
Aggregate use for waterproofing should be as per IS: 383
4) Above treatment shall be then cured for at least 24 Hours.
5) Provide water escape pipe 25 mm dia (1”) G.I. / U.P.V.C. pipe just above the base coat with filter
media fixed from inside. (Holes of such pipes should be made prior to the base coat).
6) Over the base coat, plumber shall be instructed to fit P-traps in the required level along with U.P.V.C /
C.I. outlet pipe.
7) Third coat of water proofing shall be applied with a layer of “seal roof” plaster of about 10 to 15mm
above the stone aggregate. The treatment shall be carried out on side of sunken slab and side walls up
to 2’ above finished floor level (F.F.L). The thickness of the treatment on the wall will be about 20 mm
and the mix should be of proportion 1:4.
8) The above treatment shall be cured for at least 24 hours.
9) Elastomeric / polymer coating must be required to apply on above treatment.
10) After completion of above treatment, the plumber shall finish all his plumbing work without
breaking or disturbing water proofing treatment.
Brick Bat Coba Water Proofing:
1) Select well burnt brick bats. Use of over burnt brick bats should be strictly avoided.
2) Before laying brick bats, it should be soaked thoroughly in water, for at least half an hour and then lay
the brick bat on the edge (kodi) and not on a flat surface.
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 253 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
3) Now fill the depression sunken portion with brick bats coba method with bricks laid on the edge and
not on flat surface up to required level with maintaining slope 1:60 or 80
4) Any gaps between the brick bats should be filled with mortar. Complete the brickbat coba coat with
joints filled with cement mortar 1:5 proportions. Also use water-proofing compound as per the specified
dose per bag of cement, while filling the joint.
5) The treatment shall then be cure for at least 24 hours.
6) All the holes made in the wall for P.V.C. / C.I. pipe connections should be finished with water-proofing
coba along with this coat.
7) Cure this coat by ponding water for four days and check for any leakages.
Final Coat of Water Proofing:
1) Final coat of water proofing shall now provide about 12 mm above the brick bats layer which should
be rough finished with a wire brush, for bonding of the horizontal filler coat. The final coat will have
proper slope 1:60 or 80 towards floor trap.
2) Continue this coat on the side walls, up to 45 cms (18”) above W.C. floor level. This coat should not
project out beyond the plastering coat of the W.C. walls, so as to avoid unnecessary thickness of the
glazed tile dado.
3) At the entrance door of toilet, floor level of toilet should be at least 10 mm drop with respect to
finished floor level of adjacent room or passage.
4) This final coat shall be cured for a minimum of seven days, with water up to minimum 7.5 cm depth.
5) Toilet tile joints should be filled only by using tile grout-SBR base.
Acceptance of completed works:
Type of check Acceptance
Leakage during ponding of base coat Not accepted
Leakage during ponding of Brick-bat coba Not accepted
Slope given to for neat cement over Brick-bat As per recommendation
coba
Procedures for waterproofing of Common / Open Terrace (Brick Bat Coba / Mosaic finish):
Pre Waterproofing Procedures:
1) All surfaces to be waterproofed shall be cleaned off all loose materials, mortar, oil, grease, if any,
thoroughly by wire brush. It shall be ensured that parapet plasters are completed prior to cleaning
activity is undertaken. Plaster shall be cut at one level, i.e. 1’ above terrace slab top.
2) Injection grouting shall be adopted at all major honeycombed portions, if necessary, after physical
observation of slab.
3) Terrace slab shall be cured for at least 2 days by ponding to test for leakages and to serve water
hungry concrete surface.
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 254 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
4) Ponding shall be done in areas of 5 m 2 each by forming bunds of 2” in height and cast in cement
mortar 1:10.
5) In case of major leakages, gravity grouting or pressure grouting shall be resorted to, to stop leakage.
6) Levels of water-proofing shall be clearly mark on concrete surface, clearly defining ridge line and
valley lines with level pads underneath, minimum slope being 1:100 or as that mentioned in drawing.
7) Holes for outlet pipes shall be marked clearly for size & locations and chasing shall be done thereafter.
Hole diameter shall not exceed pipe diameter. Rendering of holes shall be executed using compatible
bonding agents, (SBR based) expansive grouts, waterproofing compound and M15 grade concrete.
8) Rainwater pipes shall be fixed at the required locations as per drawing. In case of PVC pipes, surface
of pipes shall be roughened and applied with sand for proper bonding and PVC grating shall be provided
at the pipe mouths.
9) It shall be ensured that no water carrying pipes are running over the slab, which is to be water-
proofed.
10) Materials required for only 2 days of water-proofing works shall be carried to avoid unnecessary
loading of terrace slab.
During Waterproofing Procedures:
1) Bricks selected for using as Brick Bat Coba shall be either full brick, or 3/4th brick made out of one
complete brick by breaking into required size, using mallets.
2) Brick bat shall not be stored in the form of a heap at one place.
3) They shall be soaked thoroughly for about 15 minutes prior to their placing.
4) Glazed tile pieces for China Mosaic Type Water-proofing shall be soaked for about 15 minutes before
fixing.
5) After cleaning the slab, a thin layer of cement slurry shall be laid on cleaned slab prior to laying of
brick bats.
6) Over this, maximum 40 mm thick layer of cement sand mortar in the proportion 1:3 mixed with
compatible waterproofing compound shall be laid.
7) Mortar shall be preferable mixed in mechanical mixer only. Also use of plasticizer is recommended to
increase workability. Mortar prepared shall be used within 1 Hour of preparation.
8) Pre-soaked brick-bats shall then be laid in radial, by inserting brick-bats to a depth of about 15mm by
light tamping with the help of adjacent layers of brickbats shall not exceed 25mm.
9) Application of brickbats shall proceed from one corner and shall be laid in radial pattern to drain of
any water which has seeped through. Thiyya (level pads)s for the same shall be given by Site Engineer,
considering into account adequate slope. For this purpose line dories shall be fixed at every 3’ to define
the slope. Brick-bats shall be laid accordingly.
10) Edge rounding shall be done simultaneously so that bottom edge of parapet wall plaster serves as
drip mould (Kani).
11) The entire brick bat layer should be cured of minimum 3 days.
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 255 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
11) After curing is over, the surface shall be applied with a finishing coat of cement sand mortar in the
proportion 1:3 with water-proofing compound.
12) Top coat shall be of neat cement slurry of adequate consistency and shall be monolithic with brick-
bats. Surface shall be finished with 3’ long float, polish patra and line dori to mark grids of 1 X 1 sq. ft.
markings.
13) Finished surface is then tested for leakage by ponding. Ponding is done making mortar bunds of
height 1” at every 5 feet. Testing shall be carried out for 7 days.
For China Mosaic Type water-proofing, following procedure shall be adopted:
1) After curing of finishing coat (which is roughened) a layer of cement sand mortar 1:3 in proportion
and 20mm thick mixed with approved water proofing compound shall be laid over it.
2) While the bed mortar is fresh, white/coloured glass pieces shall be set closely by hand with glazed
side keeping exposed.
3) Wooden mallets shall be used for tamping China Mosaic tile pieces into place.
4) Ponding (Wattas) shall be made with mortar bedding with glazed tile pieces on top.
5) Surface of tiles shall be lightly rolled with wooden roller taking care that no hollow pockets are left
underneath glazed tile pieces.
6) Top surface shall be cleaned with saw dust or cotton waste and if necessary with weak acid solution
to remove stains of cement. Due care is taken to see to it that cement in the joints does not dissolve in
the acid solution.
7) Slope of finished top shall be 1:100 or as mentioned on the drawing.
8) Finished surface shall be cured for at least 7 days by flooding and checked for leakages/dampness, if
any.
Post Waterproofing Procedures:
Date of finishing shall be marked on the surface for curing by ponding for about 7 days.
NOTES:
Waterproofing once done, shall not be broken, or pierced. If waterproofing is to be punctured, due
care shall be taken to limit the damage to the restricted area. The cracks due to hammering shall not
spread over the large area.
Repairing of the punctured area shall be done by using bonding agent and expansive grout.
Acceptance of Completed work
Open Terrace :( Brick-Bat Coba )
Type of check Acceptance
Entire terrace to be flooded with water for 7 days No leakage should be observed from underneath.
after top coat application, blocking all rainwater
pipes.
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 256 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
After the test is over, temporary blockages of rain Water should be drained off completely
water pipes are removed. without any stagnation
Slope given to waterproofed area As per drawing
Rain water pipes Projecting ½” inside terrace and provided with
grating. Hole rendered with non-shrink grout.
Rounding at edges of parapet Merged inside wall plaster on parapet wall
Final coat of neat cement Smooth finish
Common Terrace: ( China Mosaic )
Type of check Acceptance
Undulations on finished surface Shall not be observed
Leakages/Damp spots after ponding Shall not be observed
Water stagnation Shall not be observed
Rain water outlets Shall be blocked in final coat
Procedures for Box-type Water-proofing for Underground Water Tanks:
Pre Waterproofing Procedures:
1) Ground shall be excavated at least 750 mm beyond the external faces of the walls of RCC tanks, the
additional excavated space acting as working space.
2) If water table already exists within the excavated area, then the excavated area shall be kept
sufficiently dry by creating a bund all rounds.
3) Bund shall be created with the help of sand bags filled with puddle and gaps between sand bags being
filed with puddle.
4) The area shall then be dewatered using a dewatering pump of suitable capacity ranging from 2 Hp to
5 Hp depending upon amount of water to be removed.
5) Shahabad stones received on site shall be cut and dressed to correct sizes as required.
6) Shahabad stones shall be soaked for 2 Hours before fixing.
During Waterproofing Procedures:
1) It shall be ensured that the excavated pit is sufficiently dry before laying PCC and all the raw materials
is made available.
2) PCC proportion as mentioned on drawing shall then be laid on the ground. Thickness of PCC shall be
as per drawing.
3) Care shall be taken so that PCC is laid in perfect level without slope.
4) PCC extends at least 150 mm beyond the vertical faces of base slab. PCC shall be cured for at least 3
days.
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 257 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
5) Over PCC, 20 mm thick layer of cement sand mortar (1:4) well mixed with water proofing compound
shall be laid over the entire surface of PCC.
6) Proportion of water proofing compound shall be as recommended by the water proofing compound
manufacturer.
7) Mortar shall be preferably mixed in mechanical mixers and unloaded in MS tray and shall be used
within 1 hour of preparation.
8) Next day cement slurry is spread over water proofing layer and Shahabad stones are laid side by side
over it with 10-15 mm gaps between the stone slabs by applying a layer of water proof mortar on backs.
Mortar proportion shall be as mentioned in drawing or as specified by QA Department.
9) Gaps between stone slabs shall be filled with cement sand mortar (1:4) with water proofing
compound or as specified in drawing.
10) Laying of Shahabad stones shall be done over the entire surface of water proofing layer laid earlier.
11) Next day joints between stone slabs shall be raked to a depth of 15 mm and grouted again with the
fresh mortar.
12) Over the stone slabs, 20 mm thick layer of cement sand mortar (1:4) mixed with water proofing
compound shall be laid over the entire surface of stone slabs laid. 12 mm downgraded aggregates shall
be placed at random in this layer.
13) This layer shall be cured for 3 days before starting construction of RCC base slab and walls. RCC base
slab and walls shall be constructed monolithically and as per dimensions mentioned on the drawing.
14) Water proofing layer shall also be applied on top of the projected portion of base slab and cured as
specified.
15) Water proofing of tank walls shall not start unless tank walls are constructed to their full height and
well cured for at least 7 days.
Water Proofing over side walls:
1) A groove of width equal to thickness of Shahabad stones shall be made to the full depth of top water
proofing layer below RCC base slab as also over top of projected portion of base slab.
2) Groove shall be made with the help of round wheel cutter at a distance of 15-20 mm from external
face of base slab, all along the periphery of RCC tank.
3) Within the groove Shahabad stones shall be fixed side by side without leaving any gap between
edges.
4) At a time not more than 3 horizontal layers of stone slabs one above other shall be laid.
5) Gap between vertical slabs being laid and tank walls shall be maintained with the help of suitable
steel spacers, if required, for the purpose of suitability of vertical stone wall being laid.
6) After the vertical stone wall is erected, the external face of wall shall be applied with 8 mm thick
rough cement sand plaster and cured for 2 days. Enough roughening of this plaster shall be done when
the plaster is green.
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 258 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
7) Gap between stone wall and RCC tank wall shall then be filled with cement sand mortar (1:4) mixed
with /water proofing compound. Care should be taken so that hollow pockets are not formed behind
the vertical stone wall.
8) This sequence of erection of stone wall shall continue till the required height. (Minimum at least 300
mm above ground level)
9) After erection of stone wall, the external rough surface of stone wall shall be applied with finishing
coat of 15 mm thick cement sand mortar (1:4) and cured for 3 days before backfilling starts.
Post Waterproofing Procedures:
1) Backfilling shall start after satisfactory curing of finishing coat on external water proofing.
2) Backfilling shall be done with murrum or good quality earth in layers of 300 mm thk which are
adequately watered and compacted with rammers.
Acceptance of Completed Work:
Type of check Acceptance
Side water proofing provided At least 300 mm above ground level
Base water proofing provided At least 150 mm beyond the external face of RCC
walls
Finished coat over vertical Shahabad tiles In plumb, and corners finished properly
Other Types of waterproofing:
1) Basement Waterproofing
Bentonite waterproofing system
Box Type waterproofing system
Crystallization waterproofing system
APP Membrane waterproofing: Lift Duct, Sewage Treatment Plant, Swimming Pool, New
construction with tiles, Flower Bed.
2) Terrace Waterproofing: Option 1 / Option 2 / Option 3
3) Podium waterproofing / Kitchen & pantry / toilet – bathroom without sunk / sunk toilets / chajjas /
service area – refuse area / over deck insulation
4) Roof Garden / Podium terrace
Cementitious membrane waterproofing
Polyisoprene membrane waterproofing.
Basement Waterproofing
Bentonite Waterproofing System Raft Slab / Retaining Wall:
Providing and laying Voltex / Voltex DS Bentonite Waterproofing System on top of the PCC as per
manufacturer’s specification
Raft Slab:
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 259 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
Providing and installing Voltex / Voltex DS around all foundations (ground beams, pads, pile caps etc.),
Placing Voltex / Voltex DS over the properly prepared substrate with the dark grey (Woven) geotextile
side facing the concrete to be waterproofed (i.e. The white (non-woven)side should face the
groundwater). Overlap all adjoining edges a minimum of 100 mm and stagger ends to minimum of 300
mm. Staple or nail edges together as required to prevent any displacement before and during concrete
placement.
Retaining Wall:
Providing and applying Voltex / Voltex DS by mechanically fastening to cast concrete just prior to
backfilling (post-applied), or by utilizing the peel-adhesion properties of the Voltex / Voltex DS (pre-
applied). The needle punched geotextile fibres, which have been forced from the white (spun) side
through the bentonite and dark grey (woven) side, will be trapped within the wet concrete, and allow
the Voltex DS to remain firmly attached to the concrete after the formwork has been removed.
Bentonite Water Stoppers:
Providing and laying Bentonite waterproofing Stoppers for all construction joints detailing and rock
anchoring if required.
Box Type Waterproofing System
Providing and laying Box Type waterproofing with single layer rough Shahabad of 25mm thick.
1) Washing the existing concrete surface.
2) Laying 1:3 cement mortar base & laying Shahabad tiles in Cement Mortar 1:3 to required slope as per
drawing. Top coat of 1:3 of cement mortar.
3) Mixing an integral waterproofing compound of approved make at appropriate dosage as
recommended by manufacturer at all stages.
4) Injection grouting with non-shrink cementitious grout of approved manufacturer at construction
joints, and at vulnerable junctions
5) Item shall include curing, cleaning, giving 7 days pond test (for raft) and 10 yrs. guarantee.
Bentonite Water Stoppers:
Providing and laying Bentonite Water Stoppers for all construction joints detailing and rock anchoring if
required
Crystallization Waterproofing Systems : Positive Side
Below Basement Raft:
Providing and dry sprinkling on top of PCC prior to pouring of concrete for basement raft, proprietary
“Catalytic” in depth Crystalline waterproofing system as per manufacturer’s specification and as
approved by the engineer-in-charge to permanently fix non soluble crystalline growth throughout the
capillary tracts and pores of concrete at a speed of minimum 60-65 cms per year inside concrete.
Catalytic in depth crystalline waterproofing system shall be able to withstand at least 460 ft. of water
head pressure. Both the above characteristics shall be supported with an international test report. The
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 260 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
Catalytic in depth crystalline system or equivalent shall be sprinkled at a minimum coverage rate of 1.2
kg/sqm.
Basement Retaining Wall:
Providing and applying proprietary “Catalytic” in depth Crystalline Waterproofing system as per
manufacturer’s specification and as approved by the engineer-in-charge to permanently fix non soluble
crystalline growth throughout the capillary tracts and pores of concrete at a speed of minimum 60-65
cms per year inside concrete. Catalytic in depth crystalline waterproofing system shall be able to
withstand at least 460 ft of water head pressure. Both the above characteristics shall be supported with
an international test report. The Catalytic in depth crystalline system or equivalent shall be sprinkled at a
minimum coverage rate of 1.2 kg/sqm on the honeycomb free, retaining wall.
Bentonite Water Stoppers:
Providing and laying Bentonite Water Stoppers for all construction joints detailing and rock anchoring if
required
Crystallization Waterproofing System: Negative Side
Above Basement Raft:
Providing and applying Slurry on top of PCC prior to pouring of concrete for basement raft, proprietary
“Catalytic” in depth Crystalline waterproofing system as per manufacturer’s specification and as
approved by the engineer-in-charge to permanently fix non soluble crystalline growth throughout the
capillary tracts and pores of concrete at a speed of minimum 60-65 cms per year inside concrete.
Catalytic in depth crystalline waterproofing system shall be able to withstand at least 460 ft. of water
head pressure. Both the above characteristics shall be supported with a manufacturer’s test report. The
Catalytic in depth crystalline system or equivalent shall be sprinkled at a minimum coverage rate of 1.2
kg/sqm.
Basement Retaining Wall:
Providing and applying proprietary “Catalytic” in depth Crystalline Waterproofing system as per
manufacturer’s specification and as approved by the engineer-in-charge to permanently fix non soluble
crystalline growth throughout the capillary tracts and pores of concrete at a speed of minimum 60-65
cms per year inside concrete. Catalytic in depth crystalline waterproofing system shall be able to
withstand at least 460 ft of water head pressure. Both the above characteristics shall be supported with
manufacturer’s test report. The Catalytic in depth crystalline system or equivalent shall be sprinkled at a
minimum coverage rate of 1.2 kg/sqm on the honeycomb free, retaining wall.
Bentonite Water Stoppers:
Providing and laying Bentonite Water Stoppers for all construction joints detailing and rock anchoring if
required.
APP Membrane Waterproofing
APP Membrane
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 261 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
1) Providing and laying waterproofing treatment to the basements with Double layer of 4mm thick and
3 mm thick, APP modified torch applied bituminous Polyplus or equivalent waterproofing membrane,
reinforced with 180 GSM non-woven polyester matt, including overlapping, preparing the surface free
from undulations and debris, priming the damp surfaces with water based bituminous primer @ 200
gm/m² and dry surfaces with solvent base primer @ 200 gm/sq. m. and torch applying the membrane to
the surface with staggered joints. Cost to include necessary protection to the waterproofing membrane
with 3.2 mm thick chistle resistant and puncture resistant, waterproof bituboard, asphaltic protection
board, fixed by spot torching the board.
2) Providing and laying Protective Board / Protective Screed in Cement Mortar 1:4 for protection of the
membrane.
Lift Pit
Application Instruction:
1) Cleaning the joints between the flooring and walls carefully and providing and installing the Coving
Bandage to the area to overlap the joint for prevention of seepage.
2) Cleaning the concrete surface and opening the old /construction joints and sealing the same with
polymer mortar filled with stone chips and grouting joints wherever required. Providing and applying
one coat of flexible Cementitious membrane as per manufacturer’s specification.
3) Flooring: Providing and laying Metal Coba approx. 50mm thick over the surface in Cement Mortar 1:4
laid to slope with proper Wattas at junction with false squares, curing testing complete.
4) Wall: Providing and applying one coat of plaster in CM 1:4 of 15 mm thick and adding appropriate
waterproofing compound and curing the same thoroughly.
Sewage Treatment Plant
Application Instruction:
1) Cleaning the joints between the flooring and walls carefully and providing and installing the Coving
Bandage to the area to overlap the joint for prevention of seepage.
2) Cleaning the concrete surface and opening the old /construction joints and sealing the same with
polymer mortar filled with stone chips and grouting joints wherever required. Providing and applying
one coat of flexible cementitious membrane as per manufacturer’s specification.
3) Flooring: Providing and laying Metal Coba approx. 50mm thick over the surface in CM 1:4 laid to slope
with proper wattas at junction with false squares, curing testing complete.
4) Wall: Providing and applying one coat of plaster in Cement Mortar 1:4 of 25 mm thick and adding
appropriate waterproofing compound and curing the same thoroughly.
Swimming Pool -New Construction with Tiles
Application Instruction:
1) Cleaning the joints between the flooring and walls carefully and providing and installing the Coving
Bandage to the area to overlap the joint for prevention of seepage.
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 262 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
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2) Cleaning the concrete surface and opening the old /construction joints and sealing the same with
polymer mortar filled with stone chips and grouting joints wherever required. Providing and applying
one coat of flexible cementitious membrane as per manufacturer’s specification.
3) Flooring: Providing and laying Metal Coba approx. 50mm thick over the surface in Cement Mortar 1:4
laid to slope with proper wattas at junction with false squares, curing testing complete.
4) Wall: Providing and applying one coat of plaster in Cement Mortar 1:4 of 15 mm thick and adding
appropriate waterproofing compound and curing the same thoroughly.
Flower Bed
Application Instruction:
1) Cleaning the joints between the flooring and walls carefully and providing and installing the Coving
Bandage to the area to overlap the joint for prevention of seepage.
2) Cleaning the surface thoroughly and applying two coats of flexible cementitious membrane or
equivalent chemical waterproofing system as per manufacturer’s specification to receive brick bat coba.
3) Providing and laying screed in Cement Mortar 1:4 of 25 mm thick for protection of membrane.
Terrace Waterproofing
Application Instruction: Option 1
1) Cleaning the joints between the flooring and walls carefully and providing and installing the Coving
Bandage to the area to overlap the joint for prevention of seepage.
2) Cleaning the entire terrace slab thoroughly, providing and applying one coat of primer followed by
two coats Cementitious Membrane Chemical Waterproofing System as per manufacturer’s specification
3) Providing and laying brick bat waterproofing treatment over terrace including grouting 115mm thick
avg. bbc. Laid in Cement Mortar 1:5 with proper slope with 200mm effective wattas and a top layer in
Cement Mortar 1:3 with waterproofing compound, finished smooth with false squares, curing testing
complete.
4) China Mosaic: Providing and laying China Mosaic in Cement Mortar 1:6 over the terrace
waterproofing treatment.
Application Instruction: Option 2
1) Cleaning the joints between the flooring and walls carefully and providing and installing the Coving
Bandage to the area to overlap the joint for prevention of seepage.
2) Cleaning the entire terrace slab thoroughly, providing and applying one coat of primer followed by
two coats of Polyisopreme Membrane Cementitious membrane waterproofing membrane chemical
waterproofing system as per manufacturer’s specification.
3) Providing and laying brick bat waterproofing treatment over terrace including grouting 115mm thick
average- brick bat coba laid in Cement Mortar 1:5 with proper slope with 200mm effective wattas and a
top layer in Cement Mortar 1:3 with waterproofing compound, finished smooth with false squares,
curing testing complete.
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 263 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
4) China Mosaic / Tiles: Providing and laying China Mosaic / Tiles in Cm 1:6 over the terrace
waterproofing treatment.
Application Instruction: Option 3
1) Cleaning the joints between the flooring and walls carefully and providing and installing the Coving
Bandage to the area to overlap the joint for prevention of seepage.
2) Supplying, providing and applying waterproofing treatment with Membrane type waterproofing
methods using polymer modified Bituminous Membrane of approved makes of either Styrene
Butadiene Styreen (SBS) based or Atactic Poly Propylene (APP) (UV resistant).
3) Providing and laying brick bat waterproofing treatment over terrace including grouting 115mm thick
average-brick bat coba laid in Cement Mortar 1:5 with proper slope with 200mm effective wattas and a
top layer in Cement Mortar 1:3 with waterproofing compound, finished smooth with false squares,
curing testing complete.
4) China Mosaic / Tiles: Providing and laying China Mosaic / Tiles in Cement Mortar 1:6 over the terrace
waterproofing treatment.
Podium Waterproofing
Application Instruction:
1) Cleaning the joints between the flooring and walls carefully and providing and installing the Coving
Bandage to the area to overlap the joint for prevention of seepage.
2) Cleaning the surface of slab thoroughly, making it free of all dirt and dust, opening all visible cracks
and crevices and sealing the same with Polymer mortar. Providing and applying one coat of primer
followed by two coats of Polyisopreme Membrane waterproofing membrane or equivalent
waterproofing system to receive brick laid coba /screed.
3) Providing and laying brick bat waterproofing treatment including grouting 115mm thick average- brick
bat coba laid in Cement Mortar 1:5 with proper slope with 200mm effective wattas and a top layer in
Cement Mortar 1:3 with waterproofing compound, finished smooth with false squares, curing testing
complete.
Kitchen / Pantry
Application Instruction:
Flooring
1) Cleaning the joints between the flooring and walls carefully and providing and installing the Coving
Bandage to the area to overlap the joint for prevention of seepage.
2) Cleaning the surface of the floor thoroughly and applying two coats of Cementitious Membrane or
equivalent Cementitious Waterproofing System as per manufacturer’s specification to receive brick laid
in coba.
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 264 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
3) Providing and laying brick bat waterproofing treatment including grouting 115mm thick avg. bbc laid
in Cement Mortar 1:5 with proper slope with 200mm effective wattas and a top layer in Cement Mortar
1:3 with waterproofing compound, finished smooth with false squares, curing testing complete.
4) Providing and laying protective screed in Cement Mortar 1:4 of 25mm thick for protection of the
membrane.
Walls:
1) Cleaning the joints between the flooring and walls carefully and providing and installing the Coving
Bandage to the area to overlap the joint for prevention of seepage.
2) Cleaning the wall areas thoroughly and applying two coats of flexible cementitious membrane or
equivalent cementitious waterproofing system as per manufacturer’s specification to further receive
coat of plaster.
3) Providing and applying one coat of plaster Cement Mortar 1:4 of 25mm thick and adding appropriate
waterproofing compound and curing the same thoroughly.
Toilet / Bathroom without Sunk
Application Instruction:
Flooring:
1) Cleaning the joints between the flooring and walls carefully and providing and installing the Coving
Bandage to the area to overlap the joint for prevention of seepage.
2) Cleaning the toilet surface of the floor thoroughly and applying two coats of flexible cementitious
membrane or equivalent Chemical Waterproofing System as per manufacturer’s specification.
3) Providing and laying Screed in Cement Mortar 1:4 of 25mm thick for protection of the membrane.
Walls:
1) Cleaning the joints between the flooring and walls carefully and providing and installing the Coving
Bandage to the area to overlap the joint for prevention of seepage.
2) Cleaning the toilet wall areas thoroughly and applying two coats of flexible cementitious membrane
or equivalent Chemical Waterproofing System as per manufacturer’s specification to further receive
coat of plaster.
3) Providing and applying one coat of plaster Cement Mortar 1:4 of 25mm thick and adding appropriate
waterproofing compound and curing the same thoroughly.
Sunk Toilets
Application instruction:
Flooring:
1) Cleaning the joints between the flooring and walls carefully and providing and installing the Coving
Bandage to the area to overlap the joint for prevention of seepage.
2) Cleaning the toilet surface of the floor thoroughly and applying two coats flexible cementitious
membrane or equivalent Chemical Waterproofing System as per manufacturer’s specification to receive
brick bat coba.
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Page 265 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
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3) Providing and laying brick bat waterproofing treatment including grouting 115mm thick average –
brick bat coba laid in Cement Mortar 1:5 with proper slope with 200mm effective wattas and a top layer
in Cement Mortar 1:3 with waterproofing compound, finished smooth with false squares, curing testing
complete.
Walls:
1) Cleaning the toilet wall areas thoroughly and applying two coats flexible cementitious membrane or
equivalent Chemical Waterproofing System as per manufacturer’s specification to further receive coat of
plaster.
2) Providing and applying one coat of plaster Cement Mortar 1:4 of 25mm thick and adding appropriate
waterproofing compound and curing the same thoroughly.
Chajja
Application Instruction:
1) Cleaning the joints between the flooring and walls carefully and providing and installing the Coving
Bandage to the area to overlap the joint for prevention of seepage.
2) Cleaning the chajja top thoroughly, providing and applying two coats of flexible cementitious
membrane or equivalent Cementitious Waterproofing System as per manufacturer’s specification to
receive brick laid coba.
3) Providing and laying Brick Bat Pieces in 40mm thick over chajja in Cement Mortar 1:4 desired slope
and curing the same for 4 days.
4) Providing and laying IPS finish in Cement Mortar 1:4 and curing the same for 6 days.
Service Area / Refuge Area
Application Instruction:
1) Cleaning the joints between the flooring and walls carefully and providing and installing the Coving
Bandage to the area to overlap the joint for prevention of seepage.
2) Cleaning the surface of the slab thoroughly, providing and applying two coats of flexible cementitious
membrane or equivalent Cementitious Waterproofing System as per manufacturer’s specification.
3) Providing and laying screed in Cement Mortar 1:4 of 25mm thick for protection of the membrane.
Over Deck Insulation
Application Instruction:
1) Cleaning the entire surface thoroughly, grouting the construction joints, cracks etc. In the slab, using
cement slurry grout admixed with expandable grout additive to full saturation, thereafter, providing and
applying one coat of flexible cementitious membrane or equivalent Cementitious Waterproofing System
on the RCC surface and on the vertical surface, up to 300mm including making fillets at the junction of
horizontal and vertical surfaces.
2) Providing and laying brick bat waterproofing treatment over terrace including grouting 115mm thick
average brick bat coba laid in Cement Mortar 1:5 with proper slope with 200mm effective wattas and a
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top layer in Cement Mortar 1:3 with waterproofing compound, finished smooth with false squares,
curing testing complete.
3) Providing and laying Foamular Metric extruded polystyrene thermal insulation layer of 50 mm thick,
stuck on the surface using suitable adhesive with shiplap joint etc. complete.
4) Providing and laying screed for protection in Cement Mortar 1:4 of 50mm thick.
5) Providing and laying separation sheet of chop Stand Geotextile Mat of 225 GSM over the extruded
polystyrene foam.
6) Providing and laying China Mosaic /Tiles in Cement Mortar 1:6 over the deck insulation membrane.
ROOF GARDEN / PODIUM TERRACE
Cementitious Membrane Waterproofing
Application instruction:
1) Cleaning the joints between the flooring and walls carefully and providing and installing the Coving
Bandage to the area to overlap the joint for prevention of seepage.
2) Cleaning the entire terrace slab thoroughly, providing and applying one coat of primer followed by
two coats of cementitious Membrane waterproofing membrane chemical waterproofing system as per
manufacturer’s specification.
3) Providing and laying brick bat waterproofing treatment over terrace including grouting 115mm thick
avg. bbc laid in Cement Mortar 1:5 with proper slope with 200mm effective wattas and a top layer in
Cement Mortar 1:3 with waterproofing compound, finished smooth with false squares, curing testing
complete.
4) Providing and laying Non Root Penetrating PVC Preformed membrane.
5) Providing and laying drainage board.
6) Providing and laying separation sheet of Chop Stand Geotextile Mat of 225 GSM over the extruded
polystyrene foam.
7) Providing and laying substrate.
8) Providing and laying Plants.
Polyisopreme Membrane waterproofing
Application instruction:
1) Cleaning the joints between the flooring and walls carefully and providing and installing the Coving
Bandage to the area to overlap the joint for prevention of seepage.
2) Cleaning the entire terrace slab thoroughly, providing and applying one coat of primer followed by
two coats of Cementitious Membrane and waterproofing membrane as chemical waterproofing system
as per manufacturer’s specification.
3) Providing and laying brick bat waterproofing treatment over terrace including grouting 115mm thick
average brick bat coba laid in Cement Mortar 1:5 with proper slope with 200mm effective wattas and a
top layer in Cement Mortar 1:3 with waterproofing compound, finished smooth with false squares,
curing testing complete.
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TITLE:
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Page 267 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
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4) Providing and laying Non Root Penetrating PVC Preformed membrane.
5) Providing and laying drainage board.
6) Providing and laying separation sheet of Chop Stand Geotextile mat of 225 GSM over the extruded
polystyrene foam.
7) Providing and laying substrate.
8) Providing and laying Plants.
Records :
Reference Documents :
ITP Reference No :
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NAME:
APPLICATION PROCEDURE FOR NON-
SHRINK GROUT FOR STRUCTURAL
SR. EFFECTIVE REV. MSS MANAGER MSS PROJECT CLIENT
CLIENT QA/QC
NO. DATE NO. QA/QC MANAGER SUPERVISOR
TABLE CONTENT
SR.NO DESCRIPTION
1. PURPOSE
2. LIMITATIONS
3. PROPOSED MATERIAL
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4. REFERENCES
5. DEFINATIONS
6. CLASSIFICATION OF GROUTS
7. TOOLS / EQUIPMENTS
8. EXECUTION
9 MATERIAL HANDILING / STORING
10 HEALTH, SAFETY AND ENVIRONMENT
NON- SHRINK GROUT FOR STRUCTURAL
1. PURPOSE:
This procedure defines the method and practices that will be used for non-shrink grout application
such as below structural base plates, machine pads and other similar structures where non-shrink
grout is required.
2. LIMITATIONS:
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This procedure should be applicable for the duration of the project as per the current base-line
schedule or any approved revisions to the schedule.
3. PROPOSED MATERIAL:
SIKA GROUT 114 - For grouting application with 75mm maximum thickness
BASF Master Flow 950 – For grouting with required thickness ranging from 20mm thickness and to a
maximum
depth of 100mm.
DURAGROUT & Other Similar Grout Material approved by CLIENT
4. REFERENCES:
SIKA GROUT 114 Data Sheet
DURAGROUT Data Sheet
BASF Master Flow 950 Data Sheet
SAES-Q-010 – Cement Based, Non-Shrink Grout for Structural and Equipment Grouting
PIP STS03601 - Epoxy Grout Specification
Project Specification SECTION 03600 - GROUT
ACI 351.1R-12 - Report on Grouting between Foundations and Bases for Support of Equipment
and Machinery
Project Schedule “Q”
5. DEFINITION:
Grout - is a particularly fluid form of concrete used to fill gaps. Grout is generally a mixture of water,
cement, and sand, and is employed in pressure grouting, embedding rebar in masonry walls,
connecting sections of pre-cast concrete, filling voids, and sealing joints. Grout is distinguished by its
high viscosity
Non-Shrink Grout - is a hydraulic cement grout that produces a big volume that, when hardened
under stipulated test conditions, is greater than or equal to the original installed volume; often used
as a transfer medium between load-bearing members.
Flowable Grout - a cementitious grout consistency with a flow of 125 to 145 by the flow test in
accordance with the applicable provisions of the ASTM C1437-07 & SANS test method; the flow
expressed as a percentage of the original base diameter after five drops of the flow table in 3
seconds.
Plastic Grout - a cementitious grout consistency with a flow of 100 to 125 by the flow test in
accordance with the applicable provisions of ASTM C1437-07 test method & SANS; the flow
calculated after five drops of the flow table in 3 seconds.
Working Time—time in which the grout can be placed.
Fluid Grout - a cementitious grout consistency with a time of efflux of 10 to 30 seconds when tested
by the flow cone procedure of the ASTM C939-10 & SANS test method.
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Grout Shoulder—the portion of the grout that extends beyond the base plate toward the edge of
the concrete foundation.
Cure Time - time after setting in which chemical and physical changes in the grout produces long-
term durability strength and serviceability.
6. CLASSIFICATION OF GROUTS:
Class 1 Grout – used for precision, non-shrink grouting of structural base plates, anchor
bolts, columns,
And pre-cast members.
Class 2 Grout – used for all non-precision grouting such as pipe sleeves and other
applications where
Non-shrink characteristics are not mandatory.
7. TOOLS/EQUIPMENT:
Any tools and equipment necessary to complete the work according to the requirements of PIP
REIE686 and the
Product recommendation.
8. EXECUTION:
1. Surface Preparation
Concrete foundations shall be cured for a minimum of 7 days before surface preparations
for grouting.
Remove laitance and oil-soaked or damaged concrete with chipping hammer to sound
fractured aggregate, or to a minimum of the top 1 inch (25 mm) of concrete. Bearing
surfaces to be grouted shall be roughened to expose course aggregate (Proj. Specs.).
When surface chipping is complete, remove all dust and loose particles with clean, dry, oil-
free air.
Concrete surfaces in contact with the epoxy grout shall be clean and dry at time of
placement. Air used for blowing shall be clean, dry, and oil -free.
After cleaning, protect the foundation surface from contamination by applying protective
sheeting.
Suitable shelter or enclosures shall be provided to protect the foundation and baseplate
from direct sunlight, dew, rain, or other inclement weather. During cold weather, adequate
enclosures and heating shall be provided to maintain foundation and baseplate
temperature within the acceptable range specified by the grout manufacturer. This
temperature shall be maintained until the grout has cured or until directed by the grout
manufacturer.
Pre-soak all concrete surfaces to be grouted for 24 hours prior to a placing Class I and Class
II, grouting. (Proj. Specs.)
2. Formwork
Grout Formwork, where required, shall be constructed with adequate strength, rigidity and
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required dimensions to permit grout placement and avoid leakage.
Attach grout forms to concrete with drilled anchors or other method when approved by
the buyer. Power nailing is not permitted.
Apply three coats of paste wax (if found necessary) to the inside surface of forms or use
other methods as recommended by the epoxy grout manufacturer to prevent grout
adherence. Oil or liquid wax is not permitted.
Install 1-inch (25-mm) 45° chamfer strips at each vertical corner and at the horizontal
surface of the grout forms.
Seal all form joints and interface between forms and concrete foundation using grout
manufacturer’s recommended sealant.
Anchor bolts shall be protected by sleeves, and exposed threads shall be
Wrapped with duct tape to prevent adherence of epoxy grout. Anchor bolt sleeves shall be
extended to the underside of the mounting plate, or the area from the top of the anchor
bolt sleeves and the bottom of the mounting plate shall be sealed to exclude epoxy grout.
3. Installation of Epoxy Grout
Prior to grouting, concrete repair have been performed in accordance with SAIC-Q-1062 as
based on SAER-5803
An adequate quantity of grout shall be on hand before starting to mix and place grout. No
partial units of epoxy, resins, hardener, or aggregate shall be used. The ratio of
components shall not be varied, and solvent shall not be added to change the grout
consistency.
Grout placements shall be started at one end of the forms, and the cavity shall be filled
completely while advancing toward the other end to prevent air entrapment.
The forms shall be checked for grout leaks frequently. Leaks will not self-seal and may
cause voids in the grout if not stopped. All leaks shall be sealed to prevent voids from
forming in the grout.
The grout shall be checked for voids after the grout has cured. Any voids shall be filled
according
to the epoxy grout manufacturer’s instructions.
Exposed expansion joints shall be sealed with the epoxy grout manufacturer’s
recommended sealant.
For standard temperature testing, maintain the grout mixture and the testing equipment at
a temperature of 73.4 +/- 5°F (23 +/- 3°C). (ASTM C 1107, Sec. 8.1.2)
4. Curing
When the grout's water/cement ratio is 0.4 or less, the grout shall be given a continuous
water cure (covered by wet burlap and 0.15mm polyethylene) for a minimum of 7 days.
(ASTM C309, Sec. 5.1)
Curing compounds if allowed by project specifications, shall have test reports or certificate
showing that it is in compliance with ASTM C309.
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5. TESTING
Sampling and Testing shall be performed by Approved testing laboratory.
6. INSPECTION/ACCEPTANCE REFERENCES
Work acceptance shall be in accordance to Approved Application Procedure, Product
Recommendations, Applicable client Standards and SANS and Checklist.
9. MATERIAL HANDLING/STORING:
Handling and storing shall be as per recommendation by the SIKA GROUT 114, BASF Master
Flow
950 & DURAGROUT Product instructions and applicable CLIENT Standards.
10. HEALTH, SAFETY and ENVIRONMENT:
Health, Safety and Environment issues shall be guided by approved safety procedures &
client Standard.
Work area to be kept clean, safe and easily accessible
Appropriate PPE shall be worn at all times
Safety talk shall be conducted to remind the workers about the risk involved before
commencing the activity.
Records :
Reference Documents:
ITP Reference No :
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METHOD STATEMENT FOR HDPE PIPE WORK
PROCEDURE FOR INSTALLATION, WELDING
AND TESTING
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NAME:
SR. EFFECTIVE REV. MSS MANAGER MSS PROJECT CLIENT
CLIENT QA/QC
NO. DATE NO. QA/QC MANAGER SUPERVISOR
TABLE OF CONTENTS
SR.NO DESCRIPTION PAGE NO.
1.0 1. SCOPE & GENERAL PROVISIONS
1.1 SCOPE
1.2 GENERAL (OVERVIEW)
1.3 RESPONSIBILITIES
2.0 REFERENCES
3.0 TERMS & DEFINITIONS
4.0 SAFETY FIRST
4.1 SAFETY ALERTS
4.2 READ AND UNDERSTAND
4.3 GENERAL SAFETY
4.4 WEAR SAFETY EQUIPMENT
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4.5 UNITS WITH HYDRAULICS
4.6 HEATERS ARE NOT EXPLOSION PROOF
4.7 ELECTRIC MOTORS ARE NOT EXPLOSION PROOF
4.8 ELECTRIC SAFETY
4.9 CRUSH POINT
4.10 FACER BLADES ARE SHARP
4.11 HEATER IS HOT
4.12 FUSION PROCEDURE
4.13 UNITS WITH GAS ENGINE
4.14 UNITS WITH BATTERY
4.15 HAVE TIERS PROPERLY SERVICED
4.16 PERIODICALLY CHECK TEMPERATURE
4.17 FUSION TOW SPEED
4.18 FUSION MACHINE POSITIONING
4.19 EDGE OF DITCH
4.20 TRACK-STAR FUSION MACHINE
4.21 TRACK-STAR MACHINE TOWING
SR.NO DESCRIPTION PAGE NO.
4.22 PPE
4.23 GUARDING AGAINST STATIC ELECTRICITY AND GASEOUS IGNITIONS
5.0 QUALITY CONTROL
6.0 STORAGE & HANDLING
6.1 STORAGE
6.2 HANDLING
7.0 INSTALLATION INSTRUCTIONS
7.1 WORK FLOW CHART
7.2 ACCESSORIES AND SPECIAL TOOLS
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7.3 BEFORE START
8.0 APPLICATIONS
8.1 WELDING CONDITIONS
8.2 PIPE ALIGNMENT
8.3 PREPARATION OF PIPE ENDS
8.4 WELDING PARAMETERS
8.5 HEATING OF SURFACE
8.6 FUSION OF SURFACE
8.7 HOLDING
8.8 COOLING OF SURFACE
9.0 INSPECTION
9.1 WELDING CHECKS
9.2 DEFECTS AND CAUSES
9.3 RULES FOR BUTT WELD FUSION
9.4 REPORT
10.0 PRESSURE TESTING
10.1 PRESSURE TESTING OUTSIDE THE TRENCH
10.2 Pressure Testing Inside the Trench
1- SCOPE & GENERAL PROVISION
1.1- Scope
The scope of this model specification is for municipal water pipelines which conform to ASTM / SANS / AWWA
standards. This model specification provides minimum requirements for HDPE pipe and fittings to be used in the
design and construction of municipal pressure piping projects.
This document describes the Safety, Quality, Inspection, Preparation and Welding Procedure of the polyethylene
pipe & fittings by fusion weld, it is to insure that the welded joint will perform equal to or greater than pipe.
This section specifies high density polyethylene pipe (HDPE) and fittings for water utility use as indicated on the
Drawings, and as specified herein.
• Furnish, Install, and Test HDPE pipe as indicated and specified in this section, and as referred to in related
sections, and the Drawings for the Project.
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METHOD STATEMENTS
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PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
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• The primary installation method is burial. The means and methods, including the testing for acceptance shall
conform to all applicable standards as noted herein with the intention of providing a leak-free system to the
owner.
1.2- General (Overview)
In butt fusion joining, mating surfaces are prepared, mating faces are melted with a hot plate heater, the heater is
removed, and the melted surface are pressed together and held under pressure. As the molten material cool, they
mix and fuse into a permanent, (homogeneous) monolithic joint. MINING SERVICES & SUPPLIES pipe fusion
procedure require special tools & equipment for the size of pipe and fittings being joined.
Responsibilities
The following duties are not limited and will be added to those mentioned in QA Manual.
Management – Shall review/approve all the procedures and are prepared as per engineering design requirements.
Quality and safety is implemented, maintained and monitored systematically.
Engineer – shall prepare all the procedures before commencing of work. Must Ensure/monitor/supervise all work
is being carried out as per engineering design requirements. Must carry out tool box talk, Checks, Inspects and
Reports to Project Manager or higher management. Must raise NCR if the work is fall out of the acceptable criteria.
Keep follow-ups with the corrective actions.
Welder – Shall Prepare the Weld joint and keep welding parameters as specified in the welding procedure. Must
follow safety measure and precautions strictly.
2- REFERENCES
To the extent referenced in this specification section, the standards and documents listed below are included, and
made a part of this specification.
In the event of a conflict, the requirements of this specification section prevail.
Unless otherwise specified, references to documents shall mean the latest published edition of the referenced
document in effect at the bid date of the project.
ANSI/AWWA
• ANSI/AWWA C901-08 Polyethylene (PE) Pressure Pipe and Tubing, ½ In. (13 mm) Through 3 In. (76 mm) for
Water Service
• ANSI/AWWA C906-07 Polyethylene (PE) Pressure Pipe and Fittings, 4 In. (100 mm) Through 63 In. (1,600 mm),
for Water Distribution and Transmission
• ANSI/AWWA C651 Standard for Disinfecting Water Mains
• AWWA M55 Manual of Water Supply Practices, PE Pipe–Design and Installation
Plastics Pipe Institute, PPI
• PPI Handbook of Polyethylene Pipe – 2009 (2nd
• PPI TR-33 Generic Butt Fusion Joining Procedure for Polyethylene Gas Pipe Edition)
• PPI TR-34 Disinfection of Newly Constructed Polyethylene Water Mains
• PPI TR-41 Generic Saddle Fusion Joining Procedure for Polyethylene Gas Piping
• PPI TN-42 Recommended Minimum Training Guidelines for PE Pipe Butt Fusion Joining Operators for
Municipal and Industrial Projects (2009) NSF
• NSF / ANSI 61 Drinking Water System Components–Health Effects ASTM
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• ASTM F 714 Standard Specification for Polyethylene (PE) Plastic Pipe (SDRPR) Based on Outside Diameter
• ASTM F905 Standard Practice for Qualification of Polyethylene Saddle-Fused Joints
• ASTM F 1055 Standard Specification for Electro fusion Type Polyethylene Fittings for Outside Diameter
Controlled Polyethylene Pipe and Tubing
• ASTM F 1290 Standard Practice for Electro fusion Joining Polyolefin Pipe and Fittings
• ASTM F 1412 Standard Specification for Polyolefin Pipe and Fittings for Corrosive Waste Drainage Systems
• ASTM F1417 Standard Test Method for Installation Acceptance of Plastic Gravity Sewer Lines Using Low-
Pressure Air
• ASTM F 2164 Standard Practice for Field Leak Testing of Polyethylene (PE) Pressure Piping Systems Using
Hydrostatic Pressure
• ASTM F2206 Standard Specification for Fabricated Fittings of Butt-Fused Polyethylene (PE) Plastic Pipe, Fittings,
Sheet Stock, Plate Stock, or Block Stock
• ASTM D 2239 Standard Specification for Polyethylene (PE) Plastic Pipe (SIDRP) Based on Controlled Inside
Diameter
• ASTM D 2321 Standard Practice for Underground Installation of Thermoplastic Pipe for Sewers and Other
Gravity-Flow Applications
• ASTM F 2620 Standard Practice for Heat Fusion Joining of Polyethylene Pipe and Fittings
• ASTM D 2683 Standard Specification for Socket-Type Polyethylene Fittings for Outside Diameter-Controlled
Polyethylene Pipe and Tubing
OPI Oxford Plastic Inc • ASTM D 2737 Standard
PPI Plastic Pipe Institute Specification for Polyethylene
AWWA American Water Works Association (PE) Plastic Tubing
ASTM American Society of Testing and Materials • ASTM D 2774 Standard Practice
for Underground Installation of
FMS Factory Mutual Standards
Thermoplastic Pressure Piping
NSF National Sanitation Foundation • ASTM D 3261 Standard
HDPE High Density Polyethylene Specification for Butt Heat
PE Polyethylene Fusion Polyethylene (PE) Plastic
PVC Poly Vinyl Chloride Fittings for Polyethylene (PE)
DI Ductile Iron Plastic Pipe and Tubing
• ASTM D 3350-08 Standard
DIPS Ductile Iron Pipe Size
Specification for Polyethylene
IPS Iron Pipe Size Plastics Pipe and Fittings
CTS Copper Tube Size Materials.
ID Inside Diameter 3- TERMS & DEFINITIONS
OD Outside Diameter
PSI Pounds Per Square Inch
PSI Pounds Per Square Inch
DR Dimension Ratio
SDR Standard Dimension Ratio
PS Pressure Surge
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Tubing Property of MSS – Approved
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Perf HDPE Perforated Corrugated Tubing
FOB Freight on Board
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4- SAFETY FIRST
4.1- Safety Alerts
This hazard alert sign Appears in this manual. When you see this sign, carefully read what it says. YOUR
SAFETY IS AT STAKE.
You will see the hazard alert sign with these words:
DANGER, WARNING, and CAUTION.
Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
Indicates a hazardous situation which, if not avoided, may result in minor or moderate injury.
In this manual you should look for two other words:
NOTICE and IMPORTANT.
NOTICE:
Can keep you from doing something that might damage the machine or someone’s property. It may also be used
to alert against unsafe practices.
IMPORTANT:
Can help you do a better job or make your job easier in some way.
4.2- Read and Understand
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Do not operate fusion equipment until you have carefully read, and understand the “Safety” and “Operation”
sections of this manual, and all other equipment manuals that will be used with it. Your safety and the safety of
others depends upon care and judgment in the operation of this equipment. Follow all applicable federal, state,
local, and industry specific regulations
4.3- General Safety
MINING SERVICES & SUPPLIES cannot anticipate every possible circumstance that may involve a potential hazard.
The warnings in this manual and on the machine are therefore not all inclusive. You must satisfy yourself that a
procedure, tool, work method, or operating technique is safe for you and others. You should also ensure that the
machine will not be damaged or made unsafe by the method of operation or maintenance you choose.
Safety is important. Report anything unusual that you notice during set up or operation.
Listen
For thumps, bumps, rattles, squeals, air leaks, or unusual sounds.
Smell
Odors like burning insulation, hot metal, burning rubber, hot oil, or natural gas.
Sense
Any changes in the way the equipment operates.
See
Problems with wiring and cables, hydraulic connections, or other equipment.
Report
Anything you see, feel, smell, or hear that is different from what you expect, or that you think may be unsafe
4.4- Wear Safety Equipment
Wear a hard hat, safety shoes, safety glasses, and other applicable personal protection equipment. Remove
jewelry and rings, and do not wear loose-fitting clothing or long hair that could catch on controls or moving
machinery.
4.5- Units with Hydraulics
Although the hydraulic pressures in the machine are low compared to some hydraulically operated equipment, it is
important to remember that a sudden hydraulic leak can cause serious injury or even be fatal if the pressure is high
enough. Escaping fluid under pressure can penetrate the skin causing serious injury. Keep hand sand body away
from pinholes which eject fluid under pressure. Use a piece of cardboard or paper to search for leaks. If any fluid is
injected into the skin, it must be immediately removed by a doctor familiar with this type of injury.
NOTICE:
Wear safety glasses, and keep face clear of area when bleeding air from hydraulic system to avoid spraying into
eyes
4.6- Heaters are Not Explosion Proof
Operation of a heater in a hazardous environment without necessary safety precautions will result in explosion and
death. When operating in a hazardous environment, heater should be brought up to temperature in a safe
environment, then unplugged before entering the hazardous atmosphere for fusion.
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4.7- Electric Motors are Not Explosion Proof
Electric Motors are not explosion proof. Operation of these components in a hazardous environment without
necessary safety precautions will result in explosion or death. When operating in a hazardous environment, keep
pump motor and chassis in a safe area by using hydraulic extension hoses
4.8- Electric Safety
Always ensure power cords are properly grounded. It is important to remember that when you are working in a
wet environment with electrical devices, proper ground connections help to minimize the chances of an electric
shock.
Frequently inspect electrical cords and unit for damage. Damaged components need to replaced and service
performed by a qualified electrician.
Do not carry electrical devices by the cord.
NOTICE:
Always connect units to the proper power source as listed on the unit, or in the owner’s manual. On units with two
power cords, plug each cord into separate power circuits. Do not plug into both outlets of one duplex receptacle.
NOTICE:
Disconnect the machine from the power source before attempting any maintenance or adjustment
4.9- Crush Points
Hydraulically operated jaws are operated under pressure. Anything caught in the jaws will be crushed. Keep
fingers, feet, arms, legs, and head out of the jaw area. Always check pipe alignment with a pencil or similar object.
4.10- Facer Blades Are Sharp
Facer blades are sharp and can cut. Never attempt to remove shavings while the facer is running, or is in the facing
position between the jaws. Use care when operating the facer, and handling the unit.
NOTICE:
Disconnect power from the facer, and remove the facer blades before attempting any maintenance or adjustment.
4.11- Heater is Hot
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The heater is hot and will burn clothing and skin. Keep the heater in its insulated heater stand or sling blanket
when not in use, and use care when heating the pipe.
NOTICE:
Use only a clean non-synthetic cloth such as a cotton cloth to clean the heater plates
4.12- Fusion Procedure
Follow the procedures carefully, and adhere to all specified parameters. Failure to follow procedures could result
in a bad weld. Always follow the proper fusion procedures.
4.13- Units With Gas Engines
Handle fuel with care. Fuel is highly flammable. Do not refuel the machine while smoking or near open flames or
sparks. Always stop the engine before refueling machine. Fill fuel tank outdoors. Help prevent fires by keeping
machine clean of accumulated trash, grease, debris, and facer shavings. Always clean up spilled fuel.
Breathing exhaust gases can cause sickness or death. Always operate machine outdoors in an area with adequate
ventilation
4.14- Units with Batteries
Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause
blindness if splashed into eyes. Avoid contact with eyes, skin, and clothing. Exploding gases from battery could
cause blindness or serious injury. Keep sparks, flames and cigarettes away.
4.15- Have Tiers Properly Serviced
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Failure to follow proper procedures when mounting a tire on a wheel or rim can produce an explosion which may
result in serious injury or death. Have tires mounted by someone that is experienced, and has the equipment to
perform the job safely
4.16- Periodically Check Temperature
NOTICE:
Incorrect heating temperature can result in bad fusion joints. Check heater plate surface temperature periodically
with a pyrometer, and make necessary adjustments. The thermometer on heaters indicates internal temperature,
and should be used as a reference only
4.17- DO NOT Tow Fusion Machine
The chassis is not designed for over-road towing. Towing at speeds greater than (05) five miles per hour can result
in machine damage as well as injury. Always transport the machine by flatbed truck or similar means, and make
sure that unit is properly secured.
4.18- Position Fusion Machine
Place fusion machine on as level ground as possible, and set the brake on the rear wheel. If it is necessary to
operate machine on un-level grade, chock the wheels and block the unit to make it as stable as possible
4.19- Keep Machine Away from Edge of Ditch
Heavy equipment too close to a ditch can cause the walls of the ditch to cave-in. Keep the machine far enough
away from the edge of the ditch to prevent injury to personnel and equipment from a cave-in
4.20- Operating Trac-Star Fusion Machines
Place fusion machine on as level ground as possible.
If it is necessary to operate machine on un-level grade, make sure that the ground is stable. Some unstable
conditions maybe ice, snow, mud, and loose gravel.
For operation safety, never operate machine on a grade steeper than 30%. (A 3 foot elevation change in 10 feet.)
4.21- Do Not Attempt to Tow A Trac-Star Fusion Machine
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The machine is not designed for towing. Attempting to tow the machine can result in machine damage. Always
transport the machine by flatbed truck or similar means, and make sure that unit is properly secured.
4.22- Protective Equipment
When operating machine for more than four hours per day, wear hearing protection. Wear PPE during operation
works at all time. As specified in Safety procedures.
4.23- Safety Precautions For Guarding Against Static Electricity And Gaseous Ignition
Polyethylene plastic pipe does not readily conduct electricity. A static electricity charge can buildup on inside and
outside surfaces and stay on the pipe surface until some grounding device, such as a tool or a person comes close
enough for the static electricity to discharge to the grounding device.
Discharging one part of the pipe surface will not affect other charged areas because static electricity does not flow
readily from one area to another. Polyethylene pipe cannot be discharged by attaching grounding wires to the
pipe.
Heaters, electric facers and electric power tools are NOT explosion proof.
Static electricity discharge can ignite a flammable gas or combustible dust atmosphere.
A static electricity discharge to a person, a tool, or a grounded object close to the pipe surface can cause an electric
shock or a spark that can ignite a flammable gas or combustible dust atmosphere causing fire or explosion.
In gas utility applications, static electricity can be a potential safety hazard. Where a flammable gas-air mixture
may be encountered and static charges may be present, such as when repairing a leak, squeezing-off an open pipe,
purging, making a connection, etc., arc preventing safety precautions are necessary. Observe all procedures for
static electricity safety and control, including procedures for discharging static electricity and requirements for
personal protection.
Take steps to discharge static electricity from the surface of the polyethylene gas pipe. Such steps include wetting
the entire exposed pipe surface with a conductive anti-static liquid or a dilute soap and water solution, then
covering or wrapping the entire wetted, exposed pipe surface with grounded wet burlap, conductive poly film, or
wet tape conductor. The external covering should be kept wet by occasional re-wetting with anti-static solution.
The covering or tape should be suitably grounded such as to a metal pin driven into the ground.
Steps that discharge the outer surface do not discharge the inner surface of the pipe. Squeeze-off purging, venting,
cutting, etc., can still result in a static electricity discharge. When appropriate, ground tools and remove all
potential sources of ignition.
Key items:
Do not put a butt fusion machine chassis in a hazardous environment.
Set the chassis up out of harm’s way and use extension hoses to operate upper works in hazardous area.
Do not use a butt fusion machine with an electric facer in a gaseous environment. Use a machine equipped with a
hydraulic facer or convert the electric facer to a manual by removing the brushes and turning facer manually.
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When making butt fusions, saddle fusions and socket fusions in a hazardous environment, set the generator up out
of harm’s way and have the heater plugged into it there. Set the heater temperature at the maximum allowed for
the application. Use 450° F for butt fusion and 510° F for saddle fusion and socket fusion. These are surface
temperatures. The high side temperatures are used to compensate for the drop in temperature experienced when
heater is unplugged from the power source to make fusion in hazardous area. Unplug heater prior to using in a
hazardous environment.
Do not drill hole first prior to making a saddle fusion.
When prepping the main pipe for a saddle fusion, do not use an electric grinding tool. Prepare main pipe manually
by use of 50-60 grit utility cloth.
Do not use an electric drill for punching hole through after saddle fusion has been made.
Use your senses and good judgment: Listen, Smell, Feel, See and Report any unsafe situations you see or see
coming to your onsite contact, if corrective action is not taken in your opinion, Do not enter into the situation.
5- QUALITY CONTROL
Quality fusion requires all of the required tools and equipment, and following all of the steps in the procedure in
the correct sequence. The fusion procedure prepares and aligns the surfaces, heats the mating surfaces to the
proper melt consistency, joins the surface together under pressure, then cools the joint under pressure. Faulty
fusion is caused by improper or defective equipment, omitting steps or doing things out of the sequence. Faulty
fusion may be hazardous.
Training and experience provide knowledge and proficiency in what to do, what to expect, and recognizing
potential problems in advance. Inadequately trained or in experienced persons can produce poor quality fusions,
and they may expose themselves or other to hazards. Safety regulations require that persons making joints in gas
system must be qualified in the pipeline operator’s qualified fusion procedures.
They factors below are necessary for quality fusions are:
Use Personal Safety Equipment. Always wear a hard hat and protective boots. Gloves protect hands from
heater burns and sharp blades on the facer. Protective Eye Glasses are also a good idea.
Make sure all equipment is in good working order and power cords are free of cuts with grounding blade on
receptacle in tack.
Position fusion equipment on level ground whenever possible.
If the fusion equipment has wheels, set the wheel lock or block them.
Position pipe support stands on either side of the fusion equipment approximately 20’ from ends of the
fusion equipment. Adjust stands so that pipes are level to reduce drag.
Plug heater in on self-contained fusion units only after unit has been started and warmed up. Unplug heater
before turning fusion unit off. This will keep you from having heater element and circuitry problems with
your heater.
Load loose pipe joints into movable side of the fusion equipment and pull joints already fused through non-
movable side.
Fusion tools and equipment must be correct for the job, and in proper working order.
Check your pipe before you fuse it. Look for deep scratches, cuts and gouges. Use the 10 percent rule: Any
imperfection affecting more than 10 percent of the pipe wall being worked with should not be used.
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When rough cutting pipe, use a pipe wrap to mark the pipe with a reference line, this will aid you in making a
square and even cut. In general, tooling that works with wood works well with HDPE pipe. For cutting pipe,
skill saws and chain saws work well. When using chain saws, the cut ends MUST be cleaned with isopropyl
alcohol to remove BAR Oil Splash or any other contaminants. For cutting holes in pipe, drills with hole saws
and reciprocating saws work well.
When making fusions that involve pipe to fittings, special care should be taken. The necking down or toe in
at the pipe ends, which is normal, needs to be completely removed in the facing process. This is seen
primarily in working with the larger pipe diameters.
The fusion operator must be proficient in tool and equipment use and operation, and proficient in fusion
procedure.
Do not abuse the facer when facing pipes by using too much pressure.
When pulling pipe through the fusion equipment, elevate pipe in the machine using the pipe lifts so the
fusion bead clears all obstructions as it is pulled through
If a fusion weld does not come out exactly as you like or you question the quality of the fusion weld, then cut
it out and re-fuse. Always remember – IF IN DOUBT, CUT IT OUT and redo.
Pipe and fitting surface must be clean and properly prepared.
Fusion beads can be removed by means of external and internal bead removers without effecting the
integrity of the fusion joint.
In inclement weather and especially in windy conditions, the fusion operation should be shielded to avoid
precipitation or blowing snow and excessive heat loss from wind chill. Capping ends of pipe that are being
fused aides heater from being chilled as fusion joint is being made.
The joint area and its parts that are being fused must be completely dry. No liquid of any kind running
through the pipe or fittings is permissible.
When fusion is done in cold weather, DO NOT INCREASE HEATING TOOL SURFACE TEMPERATURE.
Do not try to shorten cooling times of fusions by applying wet cloths, water or the like.
Heating tool surfaces must be clean, undamaged and at the correct surface temperature.
When removing pipe from the fusing unit and pulling into place, use proper lifting slings and pulling heads in
good condition. Chains and rope can slip and cause injury/damage to personnel and pipe.
When working with coiled pipe 2” - 6”, a McElroy Line Tamer™ should be used to straighten and re-round
coiled pipe to meet or exceed ASTM D- 2513 Quality Requirements.
Squeeze tools can be used on HDPE Pipe to stop flow in a pipeline while a tie in or repair is made. Follow
manufacturer’s squeeze-off tool instructions.
A common obstacle when working with HDPE pipe in the field is understanding the thermal expansion and
contraction. Rule of thumb - 1.4”/ 100’/ 10ºF.
6- STORAGE & HANDLING
6.1- Storage
Method Statements must be approved for the transportation, handling and storage of pipes before any pipes are
delivered to site.
All pipes shall be handled and stored in compliance with the manufacturer's recommendations subject to the
following limitations
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Pipes shall be transported, handled and stored with such packing and in such a manner that damage does not
occur and that contact is avoided with sharp edges which may cause damage. During transit, pipes and fittings shall
be well secured and adequately supported along their length.
At every point of loading or unloading, all pipes or castings must be handled by approved lifting tackle unless
specified elsewhere. Unloading by rolling down planks or any other form of inclined ramp will not be allowed.
Pipes shall not be tipped or dropped.
Pliable straps, slings or rope shall be used to lift pipes, and steel cables or chains will not be used without written
permission.
Nesting of pipes for transportation will be permitted provided method statements demonstrate that effective
precautions will be taken to protect inner surfaces from damage.
All pipes and fittings shall be thoroughly inspected on arrival at site after off-loading and prior to installation for
detection of any damages.
Damages to coatings, if any, shall be made good in an approved manner. For other damages, proposals for repairs
shall be submitted in writing for the Engineer's approval. If in the Engineer's opinion the nature of any damage is
such that the condition of a pipe has been impaired and cannot be repaired, the pipe concerned shall not be
incorporated in the Works.
Suitably smooth and level storage areas shall be provided at or near the site and made secure to prevent
unauthorized access.
Pipes of different sizes and thickness shall be stocked separately.
6.2- Handling (Lifting)
Each site will establish Safe Operating Procedures (SOP’s) for receiving, off-loading, and storage of HDPE pipe to
ensure that:
• A load inspection checklist has been completed to verify the load has been shipped according to company
shipping requirements. These requirements are Intranet-posted document is the controlled copy. Verify printed
document is still current prior to use
• An HDPE Pipe Unloading Checklist (See Appendix D) is completed for loading or off- loading prior to beginning
the task.
• A 50-foot safe zone around the truck is established and marked, and a safety watch is in place to keep people out
of the unloading/loading zone. The truck driver will remain with the safety watch until the off-loading is complete.
• Site trucks/trailers used to move pipe sticks are equipped with engineered stints or other engineered means of
securing the load.
• Barriers or other means of preventing a line of fire issue are in place when unstrapping a load, such as using a
loader with forks to block the load.
• The site must ensure that equipment has been evaluated to ensure adequate lifting capacity and that the person
operating the equipment is aware of the limitations.
• Employees handling pipe have documented pipe handling task training.
• Receiving or warehouse personnel coordinate the safe arrival of the shipping truck with the operations
employees, and trucks will not be off-loaded until proper loading is verified utilizing the loading guidelines and the
Load Inspection Checklist. If a truck is not loaded properly, the load will be rejected or an exemption and
engineering review will be completed prior to off-loading.
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• A signed copy of the Load Inspection Checklist will be sent with the driver and presented to operations
employees (or persons unloading) prior to unloading.
• HDPE pipe is stored no more than two pipes high for 10” diameter or larger pipe, and no more than two feet for
smaller diameter pipe, unless there are engineering controls in place to control the possibility of a stack collapsing.
• An HDPE Pipe Permit will be completed prior to pulling/moving pipe.
• Each site will establish SOP’s for pulling/moving of HDPE pipe.
• All equipment used for pipe pulling/moving will meet the load specifications in MSS PROCEDURE
• For 12” diameter pipe and larger Rigging and pulling procedures for pipe less than 12” diameter will be defined in
site SOP’s.
• For pulling or moving pipe less than 12” diameter and longer than 400 feet in length, an engineering review must
be conducted and safe practices must be written into that SOP.
• The use of a sling as a “choker” is NOT acceptable for pulling/moving an HDPE pipeline of a diameter 12” or
larger unless an exemption is approved. This includes pulling lengths of pipeline while fusing in a fusing lay down
area. It is however, acceptable to use a sling to lift and position pipe (i.e. positioning a pipeline in a fusing machine
or removing it from the fusing machine). Intranet-posted document is the controlled copy. Verify printed
document is still current prior to use
• Pipe-slotting, or cutting a slot or shape in the pipeline, to be used as an anchor point for pulling/moving an HDPE
pipeline of a diameter 12” or larger is NOT acceptable unless an exemption is approved.
• All ground personnel must be positioned out of the line of fire when pipe is being pulled or moved. If the
minimum distance of 50 feet cannot be met, then substantial barriers must be utilized.
• Safety watchers and blockers will be established for pulling/moving of pipe on haul roads or where there is
potential f or interaction with other traffic as determined by risk assessment of the task.
• HDPE pipe pulls will NOT exceed grades greater than 17.5% without an approved exemption.
• Escorts and trailing vehicles must be used if pipe pulling occurs in active mining areas. Scheduling and
communication of pipe movement activities must be completed.
7- INSTALLATION INSTRUCTIONS
7.1- Work Flow Chart
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Inspection Pipe Storage Pipe Handling
Pipe Delivery
Preparation Pipe Pipe Laying
for Welding Alignment
Welding Inspection and Pressure test
Process Report
7.2- Equipment and Special Tools
Generator to supply the heater plate, trimmer and hydraulic pump.
Butt-fusion machine fitted with the correct size clamp shells, trimmer, heater plate, hydraulic pump and
timer.
Pipe support rollers
Welding tent
Cleaning material, lint free cotton cloth or paper towel
External/Internal de-beading tool
Bead gauge
Digital thermometer with surface probe to check heater plate.
Pipe end covers
Baseboard
Pipe cutters
Air temperature thermometer
Indelible marker pen
Timer.
7.3- Before Start
Inspect pipe length and fittings for unacceptable cuts, gouges, deep scratches or other deleterious defects.
Damage productions should not be used.
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Toe-in or necking down is normal at pipe end, but may need to be removed for butt fusion to fittings. Ensure
toe-in does not result in excess wall misalignment.
Remove Surface damage at pipe ends that could compromise the joining surface or interfere with fusion
tools or equipment.
Be sure all required tools and equipment are on site, in proper working order and fueled up.
The pipe and fitting surface where tool and equipment are fitted must be clean and dry. USE CLEAN, dry,
non-synthetic (Cotton) cloths or paper towels to remove dirt, sand and other contamination.
Shield heated fusion equipment and surfaces from inclement weather and winds. A temporary shelter over
fusion equipment and the fusion operation may be required.
Relieve tension in the line before making connections.
Pipe must be correctly aligned before making connections.
8- APPLICATIONS
8.1- Welding Conditions
Wind and Precipitation - Heating tool shall be shielded in insulated container to prevent excessive heat loss.
Shield the pipe fusion area and fusion tools from wind, snow, blowing dust and rain by using a canopy or
similar device. Open pipe ends should be covered with plugs or covers to protect the heater from
unacceptable temperature variations. Protective measures with auxiliary heating is recommended when
temperatures are below -4°F (-20°C).
Pipe and Fitting Surface Preparation – The pipe and fitting surfaces to be “joined” or held in clamps shall be
dry and clean and free of ice, frost, snow, dirt, and other contamination. After regular procedure for facing,
the surface shall be protected from contamination until joined
Heating – Check the temperature of the heating tool regularly with a pyrometer or other surface
temperature measuring devise. Do not increase heating tool temperature above the specified temperature
(450°F - 232°C) setting. Work quickly once pipe and fittings have been separated from the heating tool; so
that melt heat loss is minimized, but still take time (no more than 3 seconds) to inspect both melt patterns.
When the ambient temperature becomes colder, it will require a longer Heating time to develop an
indication of melt and the final bead size.
Pre-Heating – When the ambient temperature is below 3°F (-16°C), the pipe ends shall be pre-heated using a
heating blanket or warm air device to elevate the pipe temperature to improve the heating starting
condition. With pipe mounted in the fusion machine, an alternate method of pre-heating is to stop the pipe
ends within .25-.50 inches (6.4-12.7mm) of the heater plate face to allow the pipe ends to warm for 30
seconds to 2 minutes, depending on the pipe size and wall.
8.2- Pipe Alignment
The pipes must be aligned when they are clamped into the mirror welder in such a way that the surfaces are in the
same plane (parallel) to each other. The HDPE pipes can be positioned directly into the welding machine. Install the
correct adapter insert for the size of pipe diameter to be used and tighten them to the machine.
Position the pipe in a way that approx. 40mm is protruding behind the last clamp.
By doing this, you will have approx. 10 to 15mm to shave from, and the remaining 25 to 30 mm should be
sufficient for welding.
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Once the pipe has been placed in position, the top clamps can be closed. It is important to tighten the top clamp
nuts evenly in order to get a totally circular pipe, an even clamping pressure must be achieved. Then, make the
first dry matching (press the two pipes to each other) and check the amount of shaving that will be required
8.3- Welding Preparation
The welding zone must be protected from unsuitable weather conditions (e.g. humidity effects, wind and
temperatures below 0°C). The surfaces to be joined must be undamaged and free from impurities or loose
particles.
The manufacturer of the HDPE pipe should be asked to supply specific Recommendations for welding of their
products or materials. Likewise, the welding machine supplier shall supply detailed welding procedure for their
machines.
Heat fusion bonding is a combination of temperature and force resulting in two mating surfaces flowing together
to produce a joint. Fusion bonding occurs when the joint cools below the melt temperature of the material. There
is a temperature range within which any particular material may be satisfactorily joined. The specified temperature
used requires consideration of the properties of the specific material, the fusion equipment being used and the
welding environment.
The butt-welding is done in several phases and by using several parameters.
The operations can be summarized as follows:
The alignment of the pipe
The shaving of the surfaces of the pipe ends
Cold matching of the HDPE pipes
Cleaning of surfaces
Heating of surfaces
Fusion of surfaces
Cooling of weld joint
The parameters used during welding are:
Bead-up pressure in bars or psi
Bead-up height in mm or inches
Heat soaking time in seconds
Heat soaking pressure in bars or psi
Transfer time in seconds
Fusion pressure in bars or psi
Cooling time in minutes
These parameters are for information only and shall be compared with the parameters given by the HDPE pipe
manufacturer and the welding machine supplier.
8.4- Welding Parameters
After the dry matching is completed, open up the pipes and introduce the shaver.
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Turn the shaver on and adjust to suitable speed. Press the two pipes together, and shave until a continuous strip of
HDPE is peeling off on both sides of the shaver. Once constant peeling off is observed, release the pressure on the
pipes and separate the pipes. Do not turn off the shaver until the pipes are apart. If the shaver is stopped during
shaving, the shaver will create an end cut-mark and the shaving operation will have to be repeated.
Remove the shaver, match the pipes again, and check the pipe for proper alignment. Sometimes, even when
continuous peeling off is achieved on each side of the shaver, the pipes do not match properly. This is normally due
to the clamps, which are pressing on to the pipe with different pressures. Re-tightening the nuts slightly on either
side is one solution. But, if this does not help, shimming normally does the job. Open up one clamp and insert a
shim in between the jaws and the pipe. This shim will concentrate the pressure on to the pipe and move the pipe
into alignment. It is important to remember that, if the clamp has been opened during operation, the shaving
operation must be repeated.
Once the pipes are correctly aligned, separate the pipes again for cleaning. Remove chips inside the pipes on both
sides, all chips scattered under the pipes, and also inside the machine. Otherwise, they will stick to the mirror (heat
plate) later while re-heating. Remove the chips by using a brush or a small hook made out of a thin steel wire.
Never put any dirty gloves inside the pipe or remove the chips with your hands. Do not touch the shaved pipe
ends. To be on the safe side, always clean the surface with a clean rag and mineral spirits/alcohol before you
introduce the mirror.
Drag Pressure Variable
8.5- Contact Pressure 30+/- 5 psi (172 +/- 35 kPa) Heating
25 – 90 psi (172 – 620 kPa) for pipe < 1.5” the
Joining Pressure
25 – 50 psi (172 – 345 kPa) for pipe > 1.5” Surface
Heating TOOI
surface Temperature -4250F -E 250F (2180C 140C)
Heating tool surfaces must be up to temperature before fusion begins. Prior to starting, all points on both heating
tool surfaces where the heating tool surfaces will contact the pipe or fitting ends must be within the prescribed
temperature range. The temperature difference between any two points on the heating tool fusion surfaces must
not exceed 20"F (11 'C) for equipment for pipe smaller than 18-in (450 mm) diameter, or 35"F (19eC) for larger
equipment. Heating tool surfaces must be clean. For heavy wall pipe (wall thickness z 1.5'), it is preferable to be in
the lower half of the allowable temperature range.
When the properly heated mating surfaces are brought together, the force required to make the joint is the force
that is necessary to roll the fusion melt beads over to the pipe surface. This is determined visually.
Interfacial Pressures
Required interfacial pressure is used as the basis for calculating the hydraulic pressure for a hydraulic butt fusion
machine, or the applied force (measured using a torque wrench) for a manual machine, Interfacial pressures vary
based on whether the pipe wall is considered 'heavy (1.5") or not. The correct hydraulic fusion joining pressure
settings are calculated based on the type of butt fusion machine as well as the pipe OD and DR. The following
formula is used to calculate the required hydraulic pressure on a butt fusion machine.
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Where:
OD = Outside Diameter (in)
ID = Inside Diameter (in)
IP = Interfacial Pressure (psi)
PA = Piston Cross Sectional Area (in 2)
DP = Drag Pressure (psi)
For hydraulic machines, the interfacial pressure, the fusion surface area, the machine's carriage cylinder size and
internal drag pressure, and if necessary, the pressure needed to overcome external drag resistance, are used to
calculate hydraulic pressure required. The equipment manufacturer's instructions can be used as a guide to
calculate the drag pressure value.
Interfacial pressure and fusion machine hydraulic fusion joining pressure gauge settings are not the same!
For every fusion joint, the system drag force must be measured to assure the proper compensation is applied to
the fusion force. In most cases, the system drag will be the inherent drag in the hydraulic components of the
machine for which the manufacturer will have a recommended value to use. However, to assure this had not
changed due to the system set-up (ground slope or length of pipe being moved), it should be checked using the
following procedure Slowly adjust upward the machine hydraulic control, or slowly increase torque on manually
operated machines, to initiate carriage movement. The System Crag Pressure is the gauge pressure at which the
carriage starts to move on hydraulic fusion machines. The System Drag Force is the observed force or torque at
which the carriage starts to move on manually operated fusion machines. Repeat this measurement to verify the
observed reading,
Procedure allows for pipes to be misaligned up to of the minimum wall thickness. It is also allowable to fuse pipes
of unequal dimension ratios, as long as the pipes are within one standard DR increment of each other. However,
fusing two different DR's requires that the misalignment be no greater than 10% of the minimum wall thickness of
the thinner walled pipe.
Before you introduce the mirror, you should have all parameters available for this operation. Also check the mirror
temperature. Normally, the mirror has a yellow or red lamp, which tells you if the mirror has reached working
temperature. To make sure there is no cold air flowing through the pipe, place some plastic bags on each end of
the pipe, this will prevent the air from cooling the mirror on one side. You have now shaved the pipe in to a good
fit and removed the shaver and introduced the mirror.
Push the pipes together against the mirror and raise the pressure to the Bead-up pressure. This pressure needs to
be maintained until the Bead-up height has been reached. The bead up height is the height of the bead, which is
pressing up against the mirror. As soon as the Bead up height has been reached, release the pressure down to the
Heat Soak pressure. Heat soak pressure is the pressure maintained during the Heat Soak time.
As soon as the heat soak time has elapsed, separate the pipes, remove the mirror, and then press together.
8.6- Fusion the Surface
This operation has to be done quite fast, since there is actually a time limit
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“Transfer time” from the removal of the mirror until the two pipes are pressed together and reached the Fusion
pressure.
Fusion pressure is the pressure that shall reach during the Transfer time and maintained during the Cooling time.
Secure.
Clean the inside and outside Of the component (pipe or fitting) ends by wiping with a clean, dry, lint-free cloth or
paper towel remove all foreign matter. Align the components with the machine, place them in the clamps and then
close the clamps. Do not force pipes into alignment against open fusion machine clamps. (When working with
coiled pipe, f possible "S" the pipes on each side of the machine to compensate for coil curvature and make it
easier to join.) Component ends should protrude past the clamps enough so that facing will be complete. Bring the
ends together and check high-low alignment, Adjust alignment as necessary by tightening the high side down.
Face.
Place the facing tool between the components ends, and face them to establish smooth, clean, parallel mating
surfaces. Complete facing produces continuous circumferential shavings from both ends. Face until there is a
minimal distance between the fixed and moveable clamps. Some machines have facing stops. If stops are present,
face down to the stops. Remove the facing tool and clear all shavings and pipe chips from the component ends. Do
not touch the component ends with your hands after facing.
Align.
Bring the component ends together, check alignment and check for slippage against fusion pressure. Look for
complete contact all around both ends with no detectable gaps, and outside diameters in high-low alignment
(except for the misalignment permitted in section 6.1). If necessary, adjust the high side by tightening the high side
clamp. Do not loosen the low side clamp because components may slip during fusion. Re-face if high low alignment
is adjusted.
Melt.
Verify that the heating tool is maintaining the correct temperature. Place the heating tool between the component
ends, and move the ends against the heating tool. The initial contact should be under moderate pressure (known
as contact pressure) to ensure full contact. Hold contact pressure briefly then lower to drag pressure without
breaking contact. Contact pressure must be relieved at the first indication of melt completely around the pipe
ends. Procedures for releasing the pressure in the hydraulic cylinder that creates interfacial pressure vary by
manufacturer. Review the equipment manufacturers recommended procedure to ensure that only drag pressure is
applied during the soak cycle. Hold the ends against the heating tool using only drag pressure. Beads of melted
polyethylene will form against the heating tool at the component ends. When the proper melt bead Size is formed
(see Table 1), quickly separate the ends and remove the heating tool.
During heating, the melt bead will expand out flush to the heating tool surface, or may cud slightly away from the
surface. If the melt bead curls significantly away from the heating tool surface, unacceptable pressure during
heating may be indicated.
Table 1 — Melt Bead Sizes for Corresponding Pipe Sizes
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Approximate Melt Bead Size Pipe Size
(Measure from the heater plate)
1/32” – 1/16” (1 – 2mm) 1-1/4" and smaller (40 mm and smaller)
About 1/16" (2mm) Above 1-1/4" throu h 3" above 40 mm throu h 90mm
1/8" – 3/16” (3 – 5mm) Above 3" throu h B" above 90 mm throu h 225 mm
3/16” – ¼” (5 – 6mm) Above g" throu h 12" above 225 mm throu h 315 mm
¼” – 7/16” (6 – 11mm) Above 12" through 24" (above 315 mm through 630 mm)
About 7/16” Above 24" throu h 36" above 630 mm throu h 915 mm
About 9/16” Above 26" throu h 54" above g 15 mm throu h 1300 mm
About 9/16” Above 54"
Join.
Immediately after heating tool removal. QUICKLY inspect the melted ends, which should be flat, smooth, and
completely melted. If the melt surfaces are acceptable. Immediately and in a continuous motion, bring the ends
together and apply the correct joining pressure. Do not slam. Where the equipment permits, 'ramping up' to the
joining pressure is desirable. Apply enough joining pressure to roll both melt beads over to the pipe surface A
concave melt surface is unacceptable; it indicates pressure during heating. Do not continue. Allow the component
ends to cool and start over again. The Correct joining pressure will form a double bead that is rolled over to the
surface on both ends.
8.7- Holding.
Cooling time is the time in which the pipe has to be left undisturbed. Under no circumstances shall the clamps be
opened or the pressure released until the cooling time has elapsed.
Hold joining pressure against the ends until the joint is cool. The joint is cool enough for GENTLE handling when the
double bead is cool to the touch. Cool for about 30 — 90 seconds per inch of pipe diameter. Do not try to shorten
cooling time by applying water, wet clothes or the like. Avoid pulling, installation, pressure testing and rough
handling for at least an additional 30 minutes. Heavier wall thickness pipes require longer cooling times.
Inspect. On both sides, the double bead should be rolled over to the surface, and be uniformly rounded and
consistent in size all around the joint. As illustrated in Figure 3, the double bead width should be 2 to 2-1/2 times
its height above the surface, and the v-groove depth between the beads should not be more than half the bead
height.
When butt fusing to moulded fittings, the fittings side bead may have an irregular appearance, this is acceptable
provided the pipe side bead is correct. It is not necessary for the internal bead to roll over to the inside surface of
the pipe.
When butt fusing pipe of dissimilar polyethylene materials, melt bead size may vary due to differences in melt
index. This is acceptable provided the melt bead size is sufficient.
The fusion joint must be kept under fusion pressure until joint has sufficiently cooled. Maintain fusion pressure
against the piping component ends for a minimum of 11 minutes per inch (25.4mm) of pipe wall. Avoid high stress
such as pulling, installation or rough handling for an additional 30 minutes or more after removal from the fusion
machine
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9- INSPECTION
9.1- Welding Checks
The double bead should be rolled over onto the adjacent surfaces, and be uniformly rounded and consistent in size
all around the joint. As illustrated in the Figure below, all beads will not necessarily have equal size. The cleavage
between the beads must not be lower than the wall of the pipe as shown in the lower right illustration. When butt
fusing pipe to molded fittings, the fitting side bead may have an irregular appearance. This is acceptable provided
the pipe side bead is correct. It is not necessary for the internal bead to roll over to the inside surface of the pipe.
When butt fusion pipe of dissimilar polyethylene materials, melt bead size may vary due to differences in melt
index. This is acceptable provided the melt bead size is sufficient.
The mirror-welding machine, if coupled to a data log, will give a printout confirming the parameters used during
welding of a specific seam and approval/rejection of the welded seam.
9.2- Defects & Causes
BUTT FUSION TROUBLESHOOT
DEFECTS CAUSES
Excessive double bead width Overheating
Excessive joining force
Double bead v-groove too deep Excessive joining force
Insufficient heating
Pressure during heating
Flat top on bead Excessive joining force
Overheating
Non-uniform bead size around pipe Misalignment
Defective heating tool
Worn equipment
Incomplete facing
One bead larger than the other Misalignment
Component slipped in clamp
Worn equipment
Heating iron does not move freely in the
axial direction
Defective heating tool
Incomplete facing
Also possible when fusing bimodal pipes
to uni-modal pipes
Beads too small Insufficient heating
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Insufficient joining force
Bead not rolled over to surface Shallow v-groove – Insufficient heating &
insufficient joining force
Deep v-groove – Insufficient heating &
excessive joining force
Bead on bimodal pipe may have slight
gap to the pipe surface
Beads too large Excessive heating time
Square type outer bead edge Pressure during heating
Rough, Sandpaper like, bubbly or Hydrocarbon (gasoline vapors, spray
pockmarked melt bead surface paint fumes, etc.) contamination
9.3- Rules for Butt Weld Fusion
NEVER
• Attempt to weld together pipes of different SDR (wall thickness).
• Touch trimmed pipe ends.
• Leave trimming swarf inside pipe or on welding machine.
• Allow equipment to get wet or dusty.
• Use non-approved machinery.
• Remove a weld from the machine before cooling time has elapsed.
• Allow untrained personnel to use welding equipment.
• Cut corners in any part of the welding procedure.
• Weld pipes of different material on site (In factory controlled conditions it may be possible to do this).
• Use a generator of inadequate capacity
9.4- Report.
Fill out the Pre-weld and after Weld Inspection check list and report as attached with ITP for HDPE Butt Weld
Fusion. Prepare a log sheet to maintain calibration history of all equipment. Ensure tool box talk is carried out and
briefed to all workers special to operators and welders before start the work.
10- PRESSURE TESTING
10.1- Pressure Testing Outside the Trench:
If specified by the engineer, pressure testing may be conducted prior to pipe installation.
After the pipe has been joined, fill it with water, carefully bleed off any trapped air. Subject the pipe to a
hydrostatic test pressure that is 1.5 times the system design pressure for a maximum of 3 hours. During this time,
add water periodically to maintain the test pressure; this compensates for the initial stretching of the pipe. The line
pressure tightness is determined by visual observation; therefore, it is not necessary to measure the make-up
water. Examine every fused joint; any leakage must be repaired and then retested.
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NOTE: It shall be the responsibility of the contractor to ensure that appropriate safety precautions are observed
during hydrostatic testing above ground.
10.2- Pressure Testing Inside the Trench:
Fill the pipeline with water after it has been laid; bleed off any trapped air. Subject the lowest element in the
system to a test pressure that is 1.5 times the design pressure, and check for any leakage. When, in the opinion of
the engineer, local conditions require that the trenches be backfilled immediately after the pipe has been laid,
apply the pressure test after backfilling has been completed but not sooner than a time which will allow sufficient
curing of any concrete that may have been used. Typical minimum concrete curing times are 36 hours for early
strengths and 7 days for normal strengths.
The test procedures consist of two steps; the initial expansion and the test phase. When test pressure is applied to
a water filled pipe, the pipe expands. During the initial expansion of the pipe under test, sufficient make-up water
must be added to the system at hourly intervals for 3 hours to maintain the test pressure. After about 4 hours,
initial expansion should be complete and the actual test can start.
When the test is to begin, the pipe is full of water and is subjected to a constant test pressure of 1.5 times the
system design pressure. The test phase should not exceed 3 hours, after which time any water deficiency must be
replaced and measured. Add and measure the amount of make-up water required to return to the test pressure
and compare this to the maximum allowance in the table below.
An alternate leakage test consists of maintaining the test pressure (described above) over a period of 4 hours and
then dropping the pressure by 10 psi (0.69 MPa). If the pressure then remains within 5% of the target value for 1
hour, this indicates there is no leakage in the system.
NOTES: Under no circumstances shall the total time under test exceed 8 hours at 1.5 times the system pressure
rating. If the test is not complete within this time limit (due to leakage, equipment failure, etc.), the test section
shall be permitted to “relax” for 8 hours prior to the next test sequence. Air testing is not recommended.
Additional safety precautions may be required. Above procedure taken from PPI Technical Report TR-31 by the
Plastic Pipe Institute. If does not meet the engineering project requirement, a new and separate pressure
procedure shall be prepared and followed.
Records :
Reference Documents :
ITP Reference No :
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METHOD STATEMENT FOR UPVC PIPE WORK
PROCEDURE FOR INSTALLATION, WELDING
AND TESTING
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SR. EFFECTIVE REV. MSS MANAGER MSS PROJECT CLIENT
CLIENT QA/QC
NO. DATE NO. QA/QC MANAGER SUPERVISOR
TABLE OF CONTENTS
SR.NO DESCRIPTION PAGE NO.
0.0 COVER PAGE 1
0.0 TTTT TABLE OF CONTENTS 2-3
1.0 INTR INTRODUCTION 4
2.0 PROPERTIES OF UPVC 5
3.0 APPLICATIONS 5
4.0 JOINT DESCRIPTIONS 6
4.1 LOOSE COUPLERS 6
4.2 INTEGRAL SOLVENT WELD JOINT 6
4.3 INTEGRAL RING SEAL JOINT 6-7
5.0 CUTTING AND CHAMFERING 7
5.1 SOLVENT CEMENT JOINTING 8
5.1.1 SOLVENT CEMENTING PROCESS 8
5.1.2 JOINTING PROCEDURE 9 - 10
5.1.3 EXTREME CONDITION 11
5.1.4 POSSIBLE ERRORS WHEN BONDING UPVC 11 – 12
5.2 RING SEAL JOINTING 12
5.2.1 JOINTING PROCEDURE 12 - 14
5.3 THREADED JOINTS 14
5.4 SADDLE JOINTS 14
5.5 FLANGE JOINTING 14
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5.5.1 STANDARD STUB AND BACKING RING 15
5.5.2 STANDARD STUB AND ADAPTOR RING 15
5.5.3 JOINTING BOLTED FLANGE ADAPTORS 15 – 16
6.0 PIPE INSTALLATION 17
6.1 GENERAL 17
6.2 TEMPERATURE 17
6.3 TRENCH EXCAVATION 17
6.4 TRENCH WIDTH 17
6.5 TRENCH DEPTH – DEPTH OF COVER 18
6.6 RECOMMENDED MINIMUM DEPTH 18
6.7 BEDDING 18
6.8 SIDE FILL, BACKFILL AND COMPACTION 19
6.9 TEST FOR SUITABILITY OF SOIL MATERIAL FOR SURROUNDING BURIED UPVC PIPE 20
SR.NO DESCRIPTION PAGE NO.
6.10.1 METHOD 1. PARTICLE SIZE 20 - 21
6.10.2 METHOD 2. EASE OF COMPACTION 21
6.11 PIPE DEFORMATION 21 - 22
6.12 CONTAMINATED GROUND 22
6.13 PIPE BENDING RADII 23
6.14 TRENCHLESS LAYING 23
6.15 THRUSTING AND ANCHORAGE 24
6.16 ABOVE GROUND IONSTALLATION 25
6.16.1 MOUND INSTALLATION 25
6.17.2 EXPOSED INSTALLATION 25 - 26
7.0 THERMAL MOVEMENT COMPENSATION-EXPANSION REQUIREMENTS 27
7.1 BELOW GROUND 27
7.2 ABOVE GROUNG 27 - 28
7.3 VIBRATION 28
7.4 EFFECT OF SUNLIGHT 28
7.5 PROTECTION AFTER INSTALLATION 29
8.0 PIPELINE TESTING 29 - 30
8.1 PROCEED WITH THE TESTING AS FOLLOW: 30
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8.2 RECOMMENDED PRESSURE TESTING CRITERIA 30
9.0 QUALITY STANDARDS APPLICABLE TO UPVC PIPE 31 - 32
10..0 STORAGE & HANDLING 32
10.1 STORAGE 32 - 33
10.2 HANDLING (LIFTING) 33 – 34
11.0 MANHOLES CRITERIA 35 - 38
11.1 INSTALLATION INSTRUCTIONS 38
11.2 WORK FLOW CHART 38
1.0. INTRODUCTION
Plastics are synthetic macromolecular materials which, by processing acquire their specific functions. They are
produced by chemical processes, the principle raw material being oil. The macromolecular structure of plastics is
achieved by polymerization of individual molecules or monomers into chain molecules that are between 1,000 and
100,000 times larger than those naturally occurring in water or salt. This macro molecular composition forms a
spatial net‐like structure with numerous internal chemical bonds. Plastics can be divided into two main groups.
• Thermoplastic materials which, upon heating, soften and melt and can be reheated and reformed.
• Thermosetting materials which soften and melt with the initial heating but then set permanently in their final
shape.
Un-plasticized polyvinyl chloride or UPVC is one of the most widely used thermoplastic materials, due to its
flexibility of usage and competitive price. It is manufactured by the petrochemical industry who produce a
dichloride from ethane and chloride and apply pyrolysis above 400ºC to cause splitting into vinyl chloride and
hydrochloric acid.
The basic polymer is mixed with additives such as Colour, filler, lubricants and stabilizers in accordance with a
recipe determined by the properties of the finished product. The mix of compound is transported to either
extruders or injection molding machines to be converted into the end product.
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UPVC pipes and Fittings will not deteriorate under attack from bacteria or other micro‐ organism and will not
provide food source to micro / macro organisms and fungi. These Pipes and Fittings are also suitable for chemical
industries as they have chemical resistance to most acids and alkalis. UPVC being thermoplastic materials are
prone to variance in physical properties based on variation in temperature. It is important to take into account
the application of end use and temperature conditions when selecting class and rating of Pipe (Wall Thickness of
Pipe).
2.0. PROPERTIES OF UPVC
SPECIFICATIONS UPVC Units
3
Specific Gravity 1.40 – 1.43 Grams / cm
o
Specific Heat 0.25 Kcal./ Kg / C
Thermal Conductivity 0.13 Kcal. cm. HoC
‐5 0
Co‐efficient of linear Expansion (Max.) 5.0 x 10 / C
0
Vicat softening Temp. 85 C At 1 Kg. Load
0
Vicat softening Temp. 79 C At 5 Kg. Load
0 2
Tensile Strength @ 20 C (Min.) 500 Kg. / cm
Elongation (Min.) 80 %
Modulus of Elasticity 1200‐1500 Mpa.
Water Absorption <4 Mg. / cm2
Hardness – Shore D 85 – 90
Flammability Self-Extinguishing
3.0. APPLICATIONS
The UPVC pressure pipe system is suitable for the transportation of potable water for industrial and domestic
uses. Other major areas of application include:‐
• Agricultural irrigation
• Conveyance of processing fluids within industry
• Sewerage and industrial effluent disposal
• Conveyance of abrasive slurries
• Transportation of acids, alkalis and other corrosive chemicals (refer to section 4.8)
• Ground water transportation for land engineering
• Buried fire ring main
• Conduit or duct for cables and fragile piping systems
• Venting systems
• Rigid UPVC pipe should not be used at ambient or liquid temperatures in excess of 60°C for pressure
systems.
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4. JOINT DESCRIPTIONS
UPVC pressure pipe systems employ one of three jointing methods as described below
4.1. Loose couplers
Plain ended, chamfered pipe is jointed using double socket loose couplers. These either incorporate ring seals
or are for solvent weld (chemical) bonding. Jointing using loose couplers has the advantage that the nominal
length of pipe supplied is exactly the working length. No meterage is lost in making the joint.
However, as pipe has to be offered into each side of the coupler, two separate joints have to be made per
length. This will increase installation costs. As a general rule the use of loose couplers is the most expensive
method of jointing pipe, except on the very largest of diameters (400mm and over) where the saving in pipe
meterage off‐sets a good proportion of the coupling costs.
4.2. Integral solvent weld joint
One spigot end of a plain ended length of pipe is formed into a bell end. This allows the spigot end
of the next length of pipe to be inserted for solvent weld (chemical) bonding. Only one joint has to
be made per length. The effective length of a piece of pipe is reduced from its nominal length by the
depth of the belled socket. Pipe incorporating this type of joint is generally the most competitively
priced. However, installation is more time consuming than with a ring seal jointed system.
4.3. Integral ring seal joint
One spigot of a plain ended length of pipe is formed into a bell end which incorporates a seat into which is set
a synthetic rubber seal ring. Only one joint has to be made per length.
The sealing ring may be of the "Forsheda" type for imperial and metric pipes. Metric pipes may also use the
"Anger" or "Bode" type. All three types of ring seal are widely used and are approved by the WRC. The
jointing method used on imperial pipes is to BS 4346 Part 2 and the seal material is to BS 2494.
The effective length of a piece of pipe is reduced from its nominal length by the depth of the belled
socket. Ring seal jointing is the quickest method of installation and so consequently has the lowest
installation costs.
One of the major benefits of uPVC pipes is the ability to use one of the three jointing methods
below. This gives a great deal of flexibility in allowing for varying installation conditions and the skill
and equipment of the installers.
1. Solvent Cement
2. Ring Seal
3. Threaded Fittings
Before making any joint the pipe lengths and fittings should be thoroughly inspected to ensure there
is no transit damage. Any damaged items should be discarded.
5.0. CUTTING AND CHAMFERING
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The pipe should be cut using a fine tooth panel saw. It is important that the cut should be square
and to this end a miter box or similar device is recommended. If this is not available a square cut can
be obtained by using a piece of paper wound around the pipe as shown in figure.
The outside edge of the pipe end should be chamfered to approximately 15º so that at least 50% of
the wall thickness is removed at the leading edge. A chamfer of this nature is essential for both
solvent cement and rubber ring seal joints. a rasp or file can be used for this operation.
5.1. Solvent Cement Jointing
It is recommended that only solvent cements and cleaning fluid be used in the construction
of joints with uPVC pipe. When solvent cementing uPVC pipes it is useful to have a
theoretical knowledge of the chemicals and the process. Before making any joint inspect all
fittings and lengths of pipe for transit damage.
5.1.1. Solvent cementing process
• The cleaning agent does not only clean and degrease the pipe and fittings, it also penetrates the
uPVC surfaces causing them to swell and create a favorable environment for the subsequent
bonding.
• The adhesive itself also penetrates the surfaces to be bonded and this penetration is improved if
the adhesive is kept fluid longer and the surfaces have been pre‐treated with the cleaning fluid. In
cold either the penetration takes longer than in warm weather.
• Adhesives are formulated according to their usage and the type of UPVC to be bonded; only the
correct adhesive should therefore be used. It is important to check that the adhesive used is still in
good condition. Tins that contain lumps or have a heavy surface film should be discarded. Under no
circumstances should cleaning fluid be used as a thinner.
• Always use sufficient adhesive, work it in well and keep it fluid. If a less than perfect fit between
the two mating surfaces has to be filled, apply several layers of adhesive; do not allow the last layer
to dry before applying the next.
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• The two surfaces must be mated in one movement while the adhesive is still wet and the u PVC
is still soft.
• Due to the softening power of the adhesive any excess must be removed, immediately the joint
is made.
• Mated surfaces should be left undisturbed for 24 hours to allow the bond to cure.
5.1.2. Jointing procedure
To ensure a good joint the following procedure should be adhered to, also refer to the illustrations
in below figure.
• Check that the pipe end is cut square, chamfer the outside edge, deburr the inner and outer
edges of the spigot and socket.
• Make sure the fittings are clean and free from moisture by using uPVC cleaning fluid.
• Mark the spigot with a pencil or felt pen line at a distance
equivalent to the depth of the socket (see
• figures 6‐8 for pipe insertion depths). Do not score the pipe or mark with a saw.
• Dry fit the pipe into the socket ‐ an INTERFERENCE fit should be reached before the pencil mark
is completely home
• Remove the spigot form the socket and abrade both mating surfaces with heavy grade
emery paper or a bastard rasp on diameters larger than 4”/110mm. Degrease both surfaces with
suitable cleaning fluid. Using the correct uPVC solvent cement (see figure ) apply an even but not
excessive coating to the internal surface of the socket and a more generous coat to the marked pipe
end. Where the cement dries before completion (on large diameter pipes or in hot and windy
conditions) give the spigot a second coat.
• Push the pipe home and hold firmly for thirty seconds.
• Remove all excess solvent cement as quickly as possible to prevent unwanted chemical attack
on exposed joints.
• The joint should not be disturbed or strained for 5 minutes after jointing and 24 hours must be
allowed before pressure testing.
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5.1.3. Extreme conditions
Cold ‐ Under extremely cold conditions, special care must be taken to ensure excess solvent cement
is not allowed to enter into the pipeline as this could result in solvent cracking of the pipe .
Hot ‐ In hot weather, particularly when solvent cementing long lengths, the pipe should be
well ventilated. In some cases forced ventilation will be necessary.
Caution
• Ensure adequate ventilation when solvent cementing.
• If swallowed do not induce vomiting and seek medical attention.
• If splashed on face or eyes, wash liberally with clean water and seek medical attention.
• Adhesive and cleaning fluid are hazardous chemicals. Ensure that empty tins, soiled cloth and
paper are disposed of correctly and not left in the pipe trench.
5.1.4. Possible errors when bonding UPVC
• Pipe end not cut squarely.
• Pipe end not deburred and chamfered.
• Moisture and dirt on glued surface.
• Not properly cleaned or dried.
• Brush still wet with cleaner.
• Adhesive not evenly spread.
• Adhesive not brushed out axially.
• Adhesive on only one of the two surfaces.
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• Pipe and accessory not assembled in time.
• Pipe not pushed home to shoulder.
• Incorrect adhesive used. Adhesive type did not match the application.
• The gap too big to be filled completely, leaving passages through the adhesive.
• During assembly of pipe and accessories, one of the fittings has been twisted relative to the
other
• Adjusting after jointing, occurred too late, causing the already cured adhesive to be broken
apart
• The drying time not adhered to
• No attention paid to the presence of water or damp conditions (condensation)
• Ventilation too drastic causing adhesive to dry during application (skin forming)
• Adhesive no longer homogeneous, caused by the tin being left open for too long
• Use of incorrect cleaning agent
• Oil or oil containing substances contaminated joint surfaces causing bond failure
• Bonding took place at sub zero temperatures without the necessary precautions
5.2. Ring seal jointing
The assembly procedure for the uPVC pipe mechanical Joint System is outlined below,
before making any joint inspects all fittings and lengths of pipe for transit damage.
5.2.1. Jointing procedure
• Deburr and smooth the pipe spigot, cut the chamfer, and mark on a depth of entry line with a
pencil or felt pen.
• Clean both socket and ring, particularly the inside of the groove of the socket.
• Check the ring is correctly inserted, and seated. Incorrectly seated seal rings can be easily
repositioned by applying hot water to the ring seal and captivating ring (only present in
Forsheda seal rings).
• Make sure that the pipes align correctly in both planes. THIS IS MOST IMPORTANT, do not try to
insert the spigot at an angle.
• Apply joint lubricant in an even coating over half the spigot length (not the joint ring).
•For approximate coverage of rubber ring jointing lubricant. Move the spigot pipe so that the
leading
• Edge is just engaging the socket mouth before insertion.
•The flexibility of the pipe in sizes 4" and below may prevent correct alignment during assembly.
The
• force required to assemble the joint should be applied as near the spigot end as possible with the
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• Socket held in position. A twisting action will ease entry.
•Push the spigot to the depth of entry mark. This should be done with a swift movement, the
momentum gained by the spigot travelling from the socket mouth to the ring, being of assistance.
CAUTION ‐ if the pipe does not enter the socket without undue force being used, withdraw the pipe;
and re‐check the joint ring. PARTICULAR ATTENTION SHOULD BE PAID TO RING SEATING AND PIPE
ALIGNMENT.
When installing larger diameter pipe work a pipe jack may be necessary to provide the impetus to
make the joint. The use of a mechanical excavator to push the spigot home is not recommended as
this can result in over insertion and damage to the pipeline.
• The pipe should be marked (not with a saw) so that the spigot enters the socket to within 12‐
25mm of the bottom of the socket .
• If installing above ground, check entry depth after installation.
• As with all pipe jointing, cleanliness is of prime importance and pipes, especially spigot ends,
should be supported clear of the ground to prevent dirt being smeared on with the lubricant. Placing
the pipes on blocks also reduces friction and consequently facilitates the making of the joint.
THESE BLOCKS MUST BE REMOVED BEFORE BACKFILLING.
The pipeline should be pressure tested after the first 300 to 400 meters have been installed.
After this, tests should be carried out at convenient intervals preferably not exceeding 1
kilometer.
5.3. Threaded Joints
Where it is necessary to join UPVC pipe to another type of pipe using a threaded joint, we
are recommend the following guidelines:
• Wherever possible make the connection with the UPVC pipe as the male component of the joint.
• Use only P.T.F.E. tape as a sealant.
• Tighten to firm hand tightness only using strap wrenches ‐ do not use serrated jaw wrenches.
5.4. Saddle Joints
We recommend a comprehensive range of saddle joints for use with a variety of pipe sizes. Single
branch saddles are available in clamp or wedge designs and double branch clamp models in clamp
design to fit mains pipes up to 250mm diameter.
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5.5. Flange Jointing
To enable jointing of uPVC pipelines to pipes, valves or vessels of different materials uPVC flange
adaptors are available, though care has to be exercised in their use.
Allowances have to be made for the different methods of measuring uPVC pipe and for instance
ductile iron piping. For example uPVC pipe is sized according to its outside diameter and ductile iron
by its internal bore. In addition the different wall thicknesses of these different materials cause
incompatibilities between internal bore and outside diameters.
5.5.1. Standard stub and backing ring
This allows uPVC pipe to be easily attached to pipelines made from other materials and
provides a clear bore equivalent to the uPVC pipe. This may however mean that the bore of
the other pipe material is reduced down to that of the uPVC.
5.5.2. Standard stub and adaptor ring
This enables pipes of similar bores to be connected with no disruption to flow and therefore
minimal risk of blockage occurring.
5.5.3. Joining bolted flange adaptors
We recommend the following guidelines should be observed when joining pipes using
flange adaptors.
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• Ensure mating surfaces are clean and free from damage.
• Use a single rubber gasket of the correct size.
• Additional jointing compound should not be used.
• Assemble flange joints before any other joints on the pipeline.
• Mating surfaces must be aligned to within 5mm prior to bolting.
• Use only undamaged bolts, nuts and washers of the correct size.
• Ensure the gasket is properly aligned prior to bolting.
Once nuts and bolts are finger tight, and then progressively tighten as follows:
Using a torque wrench work in diagonally opposite sequence.
Tighten all bolts to 5% of final torque. Tighten all bolts to 75% of final torque
Tighten all bolts to 20% of final torque Tighten all bolts to final torque.
Tighten all bolts to 50% of final torque
Two operators should work together on pipe diameters above 180mm.
Check final torque of all bolts after one hour.
Remember a uniform tightening sequence is as important as final torque settings.
OD X Bore (mm) Torque (Nm) OD X Bore (mm) Torque (Nm)
nominal nominal
63 x 50 35 ± 5 315 X 300 120 ± 10
90 x 80 35 ± 5 355 X 350 150 ± 10
125 x 150 35 ± 5 400 X 400 200 ± 25
180 x 150 60 ± 5 450 X 450 250 ± 25
225 x 200 80 ± 5 500 X 500 300 ± 25
250 x 250 100 ± 10
6. PIPE INSTALLATION
6.1. General
The simplicity of the installation procedure for uPVC pipe offers considerable benefits especially in
terms of time and the consequent cost saving.
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uPVC pipe is a semi‐flexible conduit and as such can deflect considerably without damage. Its
response to earth loading is not governed by pipe strength, but rather by the interaction of the soil
and the pipe. It is therefore very important that all aspects of pipe laying, particularly bedding and
side fill, receive special attention.
6.2. Temperature
Particular care should be exercised when installing pipes at temperatures below 10°C. Pipe laying
should not be carried out when the temperature is below 0°C.
6.3. Trench Excavation
As a general rule trench excavation should not be carried out too far ahead of the pipe laying as
lumping and collapse of the trench wall may occur. During excavation and laying of unusually deep
pipelines the trench walls should be supported with an appropriate system to safeguard the
installation personnel against collapse of the trench. The excavated soil should be kept well back
from the edge of the trench and loose stones removed and discarded.
6.4. Trench Widths
The narrower the trench in which uPVC pipe is laid, the less the load it has to carry. Trench width
should, therefore, be kept to a minimum but it must be sufficient to allow the proper placing and
compaction of bedding material against each quadrant of the pipe. For this purpose it is
recommended that, at the crown of the pipe, the trench width should be 300mm (+50mm) wider
than the diameter of the pipe. Above the crown the trench may be any convenient width.
6.5. Trench Depth ‐ Depth of Cover
UPVC pipes may be laid with the same minimum depth of cover as pipes of other materials.
Particular attention should be given when the pipeline passes under a roadway or other load bearing
structure. Table shows recommended minimum depth of cover above the crown of the pipe for
typical situations.
6.6. Recommended minimum depth:
LOCATION DEPTH OF COVERING
ROADS & STREETS (AT MAXIMUM DOE LOADING) 1000 MM
DRIVEWAYS 750 MM
FOOTPATHS AND GARDENS 500 MM
OPEN COUNTRY 1000 MM
6.7. Bedding
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The trench should be over excavated to a depth equivalent to the nominal diameter of the pipe or a
maximum of 100mm. The under bed should be filled and thoroughly compacted with bedding
material which conforms to WIS 4‐08‐01 or meets the particle size and compaction requirements
given below.
Care must be taken to ensure continuous support is given along the entire pipe length and not just
on the joints. The bedding should be scooped out to accommodate joints and fittings.
In all cases the under bed should be laid to the correct fall and gradient.
6.8. Side fill, Backfill and Compaction
When in place in the trench the weight of overlying earth tends to force down the top of the pipe,
but for distortion to be possible, the sides must move out a corresponding distance.
Such movement of the side walls is only possible to the extent that the bedding material around the
pipe can move. The firmer that this bedding material is, the greater the force required to move it
and consequently the greater the external load the pipe can safely carry. It is, therefore, very
important that bedding and side fill material and the compaction process meet the correct
specifications.
After laying the pipe on the prepared bed, the side fill should be placed around the pipe and
compacted to 80% of optimum density, in 75mm layers, to a thickness of
the pipe diameter or a maximum of 100mm above the pipe crown. Care must be taken to avoid
displacing or damaging the pipe and to ensure that the cavities under the two lower quadrants of
the pipe are eliminated.
For the protection of the pipe initial backfilling of the trench should be carried out as soon as
possible after laying.
The remaining backfilling can be completed with “on site” spoil in well rammed layers not exceeding
300mm. Do not use heavy mechanical rammers until the pipe is covered by more than
300mm.
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6.9. Test for Suitability Of Soil Material For Surrounding Buried UPVC Pipe
The suitability of the bedding and backfilling material can be determined in one of two ways. Either
by estimating the approximate particle size or by calculating the compaction fraction of the material.
Under both methods it is necessary to obtain a representative sample of the proposed material. This
is done by taking about 50kg of the material and heaping it on a clear surface. The pile is equally
quartered and two opposing quarters are selected, the remainder is removed. The retained quarters
are remixed to form a new pile and the process is repeated until the required sample size is
obtained.
6.9.1. Method 1. Particle Size
The maximum particle size should not exceed 20mm but a small percentage of particles between
20mm and 40mm is acceptable. If particles over 40mm are present the material should be rejected.
In cases of doubt, a representative sample of the material weighing about 2kg should be sieved;
using 20mm and
40mm British Standard approved test sieves (BS 410 ‘Test Sieve’).
When sieving, clumps of material that break up under light finger pressure may be helped through
the sieve, but force should not be used to squeeze oversize lumps through the mesh. The material
should be rejected if:
a) any particles are retained on the 40mm sieve or
b) more than 5% by mass is retained on the 20mm sieve.
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For sharp, hard materials these particle size limitations should be halved (i.e. max. size 10mm and
20mm).
Where scouring of the bed under the pipeline may be caused by adverse ground water conditions
the prepared bedding material should be of a particle size smaller than 10mm to prevent loss of
support to the pipeline.
6.9.2. Method 2 .Ease of Compaction
1. Place a 250mm length of 160mm O.D. pipe on a clear surface.
2. Fill the length of pipe loosely with a representative sample of the proposed material and level off
to the top of the pipe.
3. Lift the pipe off the sample and place it on a clear surface.
4. Replace about a quarter of the sample into the pipe and compact it using a rammer of
approximately 1kg weight. Repeat this process until all the sample has been returned to the pipe.
6.10. Pipe Deformation
If the deflection of the top of a flexible pipe is steadily increased a point will be reached where it
loses support from the spread out sides and collapses into the lower portion of the pipe. Collapse
occurs when the deflection reaches about 20% of the pipe diameter. A maximum
deflection of 5% of the pipe diameter is usually accepted giving a nominal safety factor of 4. This
maximum deflection of 5% allows for new connections into the system to be easily achieved.
Where a pipeline is required to be encased in concrete as a design requirement or due to excessive
loading it must be wrapped in a non‐porous membrane such as polythene film to a thickness of 250
mu, according to Figure below. Flexible ring seal joints must be allowed to expand by the inclusion
of compressible board joint filler between each concrete pour as detailed in Figure.
6.11. Contaminated Ground
UPVC pipe is resistant to many contaminants, but where contamination is suspected but it is
recommended that a detailed soil analysis is undertaken.
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Some protection can be given to pipelines in contaminated ground by encasing the pipe in a clean
sand envelope. Additional protection can be made by the provision of a PVC‐u membrane around
the sand as shown in figure.
6.12. Pipe Bending Radii
UPVC pipe is a semi‐flexible conduit and hence gradual changes of direction can be made by laying
the pipe to a curve. The minimum radius of any such curvature is 150 times the nominal diameter of
the pipe. The maximum deflection allowed in a mechanical joint =3°.Avoid placing joints and fittings
in pipes which are to be bent, preformed bends and elbows are available to eliminate stress.
6.13. Trenchless laying
Trenchless laying of uPVC pipe has been carried out extensively and has proved successful up to
90mm/3" diameter, solvent welded pipe only.
UPVC pipe has proved suitable for mole plough and cut and feed installation techniques.
Obviously care has to be taken to minimize the induced stress on the pipe whilst pulling
in.
Pipe to be installed by this method should be prejointed in lengths not exceeding 300 meters and
the solvent welded joints given a full curing period of 24 hours before commencing laying. Following
laying the jointing of these sections can be carried out, with care taken to ensure the pipe has
reached ground temperatures.
During feed down the pipe must not be curved tighter than the following radii‐
Nominal diameter Minimum curve radii
100 mm 100 x
80 mm 80 x
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65 mm or less 65 x
Trenchless laying should only be undertaken once it has been ascertained that the soil type is
suitable and damage to the pipe will not occur.
6.14. Thrusting and Anchorage
Thrust blocks (as in figure) are needed whenever the pipeline changes direction or size, stops or has
an inline tee piece or valve. The function of these thrust blocks is to prevent deflection or extension
of the pipeline under the action of internal fluid pressure and to transfer the resultant forces
to the surrounding ground of load bearing capacity. The following figures are a guide to the design,
and position of the anchor blocks.
When placing concrete on an UPVC pipeline care should be taken to avoid encasing the pipe
completely.
This is because the slight flexibility of uPVC may cause pulsing under pressure variations which may
cause the pipe to shear at the interface between the concrete anchor and the backfill. It is
recommended that a thin membrane, such as bituminized paper, thin roofing felt or polythene film
to a thickness of about 250 mu is applied between the concrete and the uPVC pipe.
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6.15. Above Ground Installation
6.15.1. Mound Installation
Where a mound is to be made up to accommodate a pipeline above the existing ground level. The
mound must first be made up to 1000mm above the planned crown of the pipe and compacted. A
trench is then dug and the pipeline laid in the usual manner.
6.15.2. Exposed Installation
UPVC pipe is manufactured for great flexibility, this means when used in exposed applications
adequate support must be provided.
The pipeline should be as near as possible to operating temperature when installed. The clamps and
supports are then affixed to it in its expanded state. These will arrest any contraction when the
pipeline cools, but more importantly there will be no signs of sagging when the pipeline is at normal
operating temperature. Table gives recommended support spacing for horizontal pipelines, the
spacing can be doubled for vertical pipelines.
Recommended pipe support spacing-horizontal pipelines (spacing can be doubled for vertical pipe
lines.
DIAMETER 20 30 40 50 60 70 80 90 100
3/8” 16 MM 75 60
1/20” 20MM 85 70 50
¾” 25MM 90 75 55
1” 32MM 100 85 65 50
1 ¼” 40MM 110 100 80 60
1 ½” 50MM 125 115 95 70
2” 63MM 140 130 110 85 55
2” 75MM 150 140 120 95 60
3” 90MM 165 155 135 105 70
4” 110MM 185 175 155 120 80
5” 140MM 215 205 185 160 110
6” 160MM 225 215 200 170 130
8” 200MM 250 240 225 200 160
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Extra support should be given to accommodate the weight of heavy fittings and equipment and also
to protect the pipeline from the torque applied when operating valves and hydrant tees.
The pipe supports should have flat surfaces of half the diameter of the pipe or 100mm minimum
width (whichever is the greater) and not be able to damage the pipe if any movement occurs.
UPVC pipe is a good insulator of the pipe contents and this helps to prevent freezing , additionally
the flexibility of uPVC allows for expansion to accommodate the increased volume of frozen
liquids. However for operational reasons it is usual to insulate pipelines to minimize the risk of the
contents freezing. Care should be taken that insulation is waterproof or is protected by a waterproof
cover.
Provision should also be made to enable drain down of pipe runs with drain valves at the lowest
points. Horizontal pipe runs should incorporate a fall to facilitate drainage. uPVC pipelines should be
insulated from local intense heat sources such as boilers and steam pipes as this may cause
excessive thermal movement of the pipe. In addition exposed pipelines should be protected
from potential impact damage.
7. THERMAL MOVEMENT COMPENSATION‐EXPANSION REQUIREMENTS
7.1. Below ground
Where flanged, threaded or solvent bonded joints are used, the pipe temperature prior to final
connection should approximate that incurred in normal service conditions. Mechanically jointed
pipe will provide some compensation for thermal movement. In the case of fluctuating service
temperature.
7.2. Above ground
Installations above ground should incorporate expansion joints to accommodate movement. The
expansion joints should be firmly anchored to prevent movement but other guide supports
should allow the pipe to slide freely.
Where specific expansion has to be allowed for, the distributor should be contacted for further
advice.
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Mechanically jointed installations above ground must be installed so that each socket is firmly
anchored but the spigots are free to move. It is important to ensure that the socket is not able to
move either longitudinally or laterally.
Figure shows preferred fixing methods for above ground installations. The recommended method
should be used wherever possible and it is essential that lateral movement be absent from
Jointed Installations.
7.3. Vibration
Vibration ‐ Continuous vibration, particularly where threaded joints are used (e.g. connections to
water pumps) must be avoided and, where necessary, flexible joints should be used to minimize
vibration effects.
7.4. Effect of Sunlight
UPVC pipe which is exposed to direct sunlight, in hot conditions, for more than six months is likely to
lose its colour. The impact strength is also reduced but the tensile strength (an indication of
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pressure rating) remains unaltered. Tests have shown that the colour loss is limited to a depth of
0.15mm after approximately twelve months exposure.
Sunlight also causes ultra‐violet degradation to rubber seals. Therefore all seals and items with seals
fitted should be kept out of direct sunlight, in their original packaging if possible, until ready to use.
7.5. Protection After Installation
Pipe work installed inside a building or buried requires no further protection, however, if exposed to
the effects of sunlight, uPVC pipe will require protection unless in a permanently shaded position.
Pipe colour plays an important part in determining the surface temperature of the pipeline. The
darker the colour, the greater is the temperature gain due to solar radiation.
For example, in tests at an ambient temperature of 47°C PVC‐u pipe and fittings in a dark grey colour
achieved a surface temperature of 60°C, a gain of 13°C. A cream pipe kept close to the ambient
temperature. If conditions are humid and there is a breeze, cream PVC‐u pipe could achieve a
slightly lower temperature than ambient.
The importance of colour indicates that all permanently exposed pipe work would benefit from
being cream (or even aluminum) in colour. If cream pipe and fittings are not available then painting
is the simplest method of protection. Paint adheres extremely well to PVC‐u and it is usually
satisfactory to paint with a top coat only. For maximum permanence of colour, two coat paint
should be used. All Alkyd paints are suitable. Metal primers (zinc chromate) provide a suitable
undercoat.
8. PIPELINE TESTING
We recommend the following guidelines be followed for pipeline testing; however, the design or
site engineer or local conditions may require alternative testing methods. The following points
should be noted before testing begins.
• Do not use high pressure air testing.
• Allow 24 hrs after welding before testing.
• Backfill or restrain the pipeline prior to testing.
• Leave joints exposed.
• Test with all valves in fully open position.
• Test sections should not exceed 1 kilometer.
8.1. Proceed with the testing as follows:
1. Blank off all ends and bolster them against pressure.
2. Insert air bleed valves at all the highest points along the pipeline.
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3. Insert a pressure gauge capable of reading pressure changes of 1% of test pressure at the lowest
point of the pipeline.
4. Slowly fill the pipeline with water, take care to avoid risk of damage due to pressure surge.
5. Ensure all air bleed valves are open and operating correctly.
6. Gradually raise the pressure without shock loading to the test pressure specified in figure .
7. Allow the test section to stand for half an hour to equalize temperatures before proceeding with
the pressure test.
8.2. Recommended Pressure Testing Criteria.
SIMPLE PRESSURE STANDARD PRESSURE TEST
TEST PHASE 1 PHASE 2
Testing pressure 1.5 1.5 1.3
(x operating
pressure)
Test Duration 2 hours 4 hours for straight runs 3 hours up to 160mm
12 hours for pipes with O.D. 6hours over
branches 160mm O.D.
Test checks 1 hour with no extra Every 2 hours with extra Every 1 hour with no
pumping pumping ectra pumping
Allow for loss of 0.5 bar/hr 0.5 bar/hr To 0.1 bar/hr
pressure to:
9. Quality Standards Applicable to UPVC Pipe
BS3505 : Un-plasticized polyvinyl chloride (UPVC) pressure pipes for cold potable water. BS3506
: Specification for un-plasticized PVC pipe for industrial uses.
BS4346 : Part 1 Joints and fittings for use with un-plasticized UPVC pressure pipes.‐Solvent
Weld.
BS4346 : Part 2 Joints and fittings for use with un-plasticized UPVC pressure pipes.‐
Mechanical Joint
WIS 4.31.06 : Specification for blue un-plasticized UPVC pressure pipes, integral joints and
Post‐formed bends for cold potable water (underground use).
WIS 4.31.07 : Specification for un-plasticized UPVC pressure fittings and assemblies for cold
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IGN Potable water (underground use).
4.31.01 : Information and guidance note ‐ un-plasticized UPVC pipes and fittings.
IS 123 : Un-plasticized PVC pipe for water mains.
SS 1776 : Edition 5 Pressure pipes of un-plasticized UPVC for cold water pipe lines.
DS 972 : Pressure pipes and fittings of un-plasticized polyvinyl chloride for water supply. ISO
4422 : Pipes and fittings made of un-plasticized polyvinyl chloride (uPVC) for water
Supply.
ISO 161 : Thermoplastic pipes for the transport of fluids ‐ nominal outside diameters and
Nominal pressures.
DIN 19582 : UPVC pressure pipe for water supply.
NEN 7029 : UPVC pipe and couplers for pressure sewer systems.
NEN 7107 : Plastic pressure system: Tension proof couplers for UPVC pipe installation and
Test Method.
NEN7108 : Bends for use with uPVC pressure pipe.
BRL K‐502 : UPVC pressure pipe.
BRL 2013 : Rubber rings and flange gaskets for use in pressure systems.
KIWA 10 : Tension proof couplers, type “AMSTERDAM” for use with PVC‐u pipe.
KIWA 46 SBR : ring seal for use in systems for the supply of potable water.
KIWA 49 : Water pipes of un-plasticized polyvinyl chloride.
KIWA 53 : UPVC couplers and fittings.
KIWA 54 : UPVC fittings in nominal diameters 12mm to 90mm inclusive.
KIWA 63 : UPVC saddles and service connections for plastic pressure pipe systems.
KIWA 71 : Tension proof couplers for use with uPVC water supply pipe.
NBN T42‐003 : Plastic pipes ‐ general requirements
NBN T42‐110 : UPVC pipe for industrial use.
NBN T42‐111 : UPVC pipe for potable water.
NBN T42‐603 : UPVC socketed fittings with elastomeric ring seal joints for water supply under
Pressure.
10.0. STORAGE & HANDLING
10.1. Storage
Method Statements must be approved for the transportation, handling and storage of pipes before any
pipes are delivered to site.
All pipes shall be handled and stored in compliance with the manufacturer's recommendations subject
to the following limitations
Pipes shall be transported, handled and stored with such packing and in such a manner that damage
does not occur and that contact is avoided with sharp edges which may cause damage. During transit,
pipes and fittings shall be well secured and adequately supported along their length.
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 326 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
At every point of loading or unloading, all pipes or castings must be handled by approved lifting tackle
unless specified elsewhere. Unloading by rolling down planks or any other form of inclined ramp will not
be allowed. Pipes shall not be tipped or dropped.
Pliable straps, slings or rope shall be used to lift pipes, and steel cables or chains will not be used
without written permission.
Nesting of pipes for transportation will be permitted provided method statements demonstrate that
effective precautions will be taken to protect inner surfaces from damage.
All pipes and fittings shall be thoroughly inspected on arrival at site after off-loading and prior to
installation for detection of any damages.
Damages to coatings, if any, shall be made good in an approved manner. For other damages, proposals
for repairs shall be submitted in writing for the Engineer's approval. If in the Engineer's opinion the
nature of any damage is such that the condition of a pipe has been impaired and cannot be repaired, the
pipe concerned shall not be incorporated in the Works.
Suitably smooth and level storage areas shall be provided at or near the site and made secure to prevent
unauthorized access.
Pipes of different sizes and thickness shall be stocked separately.
10.2. Handling (Lifting)
Each site will establish Safe Operating Procedures (SOP’s) for receiving, off-loading, and storage of UPVC
pipe to ensure that:
• A load inspection checklist has been completed to verify the load has been shipped according to
company shipping requirements. These requirements are Intranet-posted document is the controlled
copy. Verify printed document is still current prior to use
• An UPVC Pipe Unloading Checklist (See Appendix D) is completed for loading or off- loading prior to
beginning the task.
• A 50-foot safe zone around the truck is established and marked, and a safety watch is in place to keep
people out of the unloading/loading zone. The truck driver will remain with the safety watch until the
off-loading is complete.
• Site trucks/trailers used to move pipe sticks are equipped with engineered stints or other engineered
means of securing the load.
• Barriers or other means of preventing a line of fire issue are in place when unstrapping a load, such as
using a loader with forks to block the load.
• The site must ensure that equipment has been evaluated to ensure adequate lifting capacity and that
the person operating the equipment is aware of the limitations.
• Employees handling pipe have documented pipe handling task training.
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 327 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
• Receiving or warehouse personnel coordinate the safe arrival of the shipping truck with the operations
employees, and trucks will not be off-loaded until proper loading is verified utilizing the loading
guidelines and the Load Inspection Checklist. If a truck is not loaded properly, the load will be rejected or
an exemption and engineering review will be completed prior to off-loading.
• A signed copy of the Load Inspection Checklist will be sent with the driver and presented to operations
employees (or persons unloading) prior to unloading.
• UPVC pipe is stored no more than two pipes high for 10” diameter or larger pipe, and no more than
two feet for smaller diameter pipe, unless there are engineering controls in place to control the
possibility of a stack collapsing.
• An UPVC Pipe Permit will be completed prior to pulling/moving pipe.
• Each site will establish SOP’s for pulling/moving of UPVC pipe.
• All equipment used for pipe pulling/moving will meet the load specifications in MSS PROCEDURE
• For 12” diameter pipe and larger Rigging and pulling procedures for pipe less than 12” diameter will be
defined in site SOP’s.
• For pulling or moving pipe less than 12” diameter and longer than 400 feet in length, an engineering
review must be conducted and safe practices must be written into that SOP.
• The use of a sling as a “choker” is NOT acceptable for pulling/moving an HDPE pipeline of a diameter
12” or larger unless an exemption is approved. This includes pulling lengths of pipeline while fusing in a
fusing lay down area. It is however, acceptable to use a sling to lift and position pipe (i.e. positioning a
pipeline in a fusing machine or removing it from the fusing machine). Intranet-posted document is the
controlled copy. Verify printed document is still current prior to use
• Pipe-slotting, or cutting a slot or shape in the pipeline, to be used as an anchor point for
pulling/moving an UPVC pipeline of a diameter 12” or larger is NOT acceptable unless an exemption is
approved.
• All ground personnel must be positioned out of the line of fire when pipe is being pulled or moved. If
the minimum distance of 50 feet cannot be met, then substantial barriers must be utilized.
• Safety watchers and blockers will be established for pulling/moving of pipe on haul roads or where
there is potential f or interaction with other traffic as determined by risk assessment of the task.
• UPVC pipe pulls will NOT exceed grades greater than 17.5% without an approved exemption.
• Escorts and trailing vehicles must be used if pipe pulling occurs in active mining areas. Scheduling and
communication of pipe movement activities must be completed.
11.0. MANHOLE CRITERIA
1. Slope
Sewers shall have a uniform slope and straight alignment between manholes, and be designed and
constructed in accordance with these specifications.
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
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METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 328 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
Minimum grades shall not be less than those required to produce a velocity of approximately two (2)
feet per second when the size pipe selected is flowing full and using an "n" value of 0.0l3 in the Manning
Formula.
Minimum grades shall be as follows (however, slopes greater than these are desirable):
Sewer Size Minimum Slope in Feet per l00 Feet
08" .50
10" .28
12" .22
14" .17
15" .15
18" .12
21" .10
24" .08
Pipelines shall be sized to serve buildout of the planned development. Pipe sizes shall not be arbitrarily
increased in order to take advantage of a flatter grade.
The maximum permissible velocity shall not exceed fifteen (l5) feet per second. Suitable provisions shall
be provided to break steep slopes to limit the velocities in the connecting sewer pipes between
manholes. Where it is impractical to reduce the velocity, the sewer main shall be ductile iron.
2. Drop Manhole Requirements
Drop manhole connections shall be constructed for sewers entering manholes at elevations greater than
or equal to twenty-four (24) inches above the manhole invert. Drop connections shall be ductile iron
pipe or PVC pipe backfilled in six (6) inch lifts and compacted by hand tampers. Sewer lines entering a
manhole less than twenty-four (24) inches above the manhole invert shall not enter the manhole
greater than twelve (12) inches above the manhole invert and shall be incorporated into a smooth
transition by filleting the invert.
3. Sewers Exceeding 20% Slope
Sewers on a twenty percent (20%) slope or greater shall be anchored securely with concrete anchors
and be constructed of ductile iron pipe. (See Part VII, Figure S-4, Page TD-8). Anchor spacing shall be in
accordance with the following table:
Slope Anchor Spacing
20% to 35% Not over 36'
35% to 50% Not over 24'
50% or greater Not over 16'
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FORMATE ID:
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REV NO.: 00
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METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 329 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
The first anchor shall be placed on the first joint upstream from the lower manhole. The location of the
first anchor and the maximum spacing required shall determine the number of anchors used between
manholes.
4. Sewer Junctions
At all junctions where a smaller sewer joins a larger one, the relative elevation of the inverts shall be set
to maintain the same energy gradient. Two approximate methods for securing these results which may
be used are: (l) positioning the water surface of each sewer flowing at 80% of its capacity at the same
elevation, or (2) positioning the crown of both sewers at the same elevation.
5. Minimum Size
No public sewer shall be less than eight (8) inches in diameter, except that laterals serving six (6)
connections or fewer on cul-de-sacs or as sidewalk collector lines may be six (6) inches provided that
engineering calculations and justification indicate that such line size is adequate. Minimum size for each
lateral connection is four (4) inch inside diameter. The Authority reserves the right to specify the size of
any sewer mains.
6. Manhole Requirements
Manholes for access to sewers shall be provided at all intersections with other sewers, at all points of
change in alignment, changes in pipe size or grade, and at the end of the line. The maximum distance
between manholes shall be 400 feet. All sewer lines shall be straight between manholes. A manhole
shall be constructed at the end of all lines, regardless of length.
Sewer manholes for sewers up to twenty-four (24) inch diameter shall not be less than forty-eight (48)
inch inside diameter. Manholes for sewers larger than twenty-four (24) inches and up to forty-eight (48)
inches shall have an inside diameter of not less than sixty (60) inches.
Manhole top elevations shall be above the l00-year Flood Elevation or watertight with ventilation.
Where practical manholes shall be placed on undisturbed soil. Where manholes must be installed in fill
areas, the fill shall be compacted to 95% of the optimum density, as determined by AASHTO T-99 to an
elevation not less than thirty-six inches (36") above the proposed invert before excavation begins.
Certification of compaction at the manhole location shall be provided before setting the manhole base.
7. Ventilation
Ventilation of gravity sewers shall be provided where continuous watertight sections greater than l000
feet in length are incurred. Vents shall be protected against the 25-year flood level either by elevation or
mechanical means.
8. Depth of Cover
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PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 330 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
All sewers should be constructed in such a manner that a minimum of three (3) feet of cover is
maintained between the top of the pipe and the finished grade elevation. Only under extraordinary
conditions shall any sewer line be installed with less than three (3) feet of cover from the top of the pipe
to finished grade. This will only be allowed by special permission from the Authority. If such a condition
arises, the pipe shall be ductile iron, Class 52, and adequately protected. Greater depths may be
required if deemed necessary to provide service to adjacent properties or to serve lower-lying
properties. PVC pipe shall not be used when the final cover over top of the pipe exceeds fifteen (15)
feet.
12.0. INSTALLATION INSTRUCTIONS
12.1. Work Flow Chart
Inspection Pipe Storage Pipe Handling
Pipe Delivery
Preparation Pipe Pipe Laying
for Welding Alignment
Welding Inspection and Pressure test
Process Report
Records :
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FORMATE ID:
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REV NO.: 00
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DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 331 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
ITP Reference No :
METHOD STATEMENT
FOR
JOINARY WORK
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FORMATE ID:
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REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 332 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
SR. EFFECTIVE REV. MSS MANAGER MSS PROJECT CLIENT
CLIENT QA/QC
NO. DATE NO. QA/QC MANAGER SUPERVISOR
JOINARY WORK
1. Objective:
This work procedure enumerates the scope of Joinery work to be executed in the superstructures of different
buildings as a door Frames & Doors as specified in the approved drawings and at places when instructed by
the Engineer-in-charge as per approved specifications.
2. Applicability:
This procedure is applicable to the Joinery work for Main Building & substation Building.
3. Reference Document:
Tender Specifications
Drawings
Standard & Codes
Manufacturer’s Guidelines
4. Equipments:
Safety Glasses, Measuring Rule, Straight Edge, Hammer, Nail picking hammer, Pencil, 2" or 3'Carpenter's
Level ,Water Level, files , saw, chisels, wood planer, Mini drill machine, wood cutting machine, cutting
players , screw drivers, Line, Chalk and Anchor Fasteners.
5. Procedure:
Preparatory works:
Flush doors shall be of sizes, section details as shown on the drawings. The details shown on the drawings
indicate generally the sizes of the component parts and general standards. These may be varied slightly to suit
the standards adopted by the Manufacturer. Before proceeding with any manufacturing Complete
manufacturing and installation drawings for approval are required and no work shall be performed until the
approval of these drawings is obtained. Details, hardware as well as connection of doors frames and other
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METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 333 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
work to adjacent work. Samples of all joints and methods of fastening and joining shall mention clearly well
in advance of commencing the work.
Samples: -
Samples of doors, louvers etc. shall be fabricated, assembled and submitted for approval. They shall be of
sizes, types etc. as per specifications. All samples shall be provided at the cost of the contractor.
Sections:-
Frames of doors shall be fabricated from extruded section of profiles as per drawings.
Handing and Stacking:-
Fabricated materials shall be stacked in an approved manner to protect the material against any damage
during transportation. The loading and unloading shall be carried out with utmost care, on receipt of materials
at site, they shall be carefully examined to detect any damaged pieces. Arrangements shall be made for
expeditious replacement of damaged pieces/parts. Materials found to be acceptable on inspections shall be
repacked in crates and stored safely.
Where wood comes into contact with masonry brick work, concrete, plaster or dissimilar metals, it shall be
coated with approved insulation lacquer, paint or plastic tape to ensure that decaying is avoided placing the
doors in their respective openings. After the doors have been fixed in their correct assigned position, the open
hollow sections abutting masonry concrete shall be fitted with approved polysulphide sealant densely packed
and neatly finished. The doors being set straight in plumb, level and for their satisfactory operation after fixing
is complete.
Installation: -
Just prior to installation the doors shall be uncarted and stacked on edge on level bearers and supported
evenly. The frame shall be fixed into position true to line and level using adequate number of expansion
machine bolts, anchor fasteners of approved size and manufacturer and in an approved manner. The holes in
concrete/ masonry members for housing anchor bolts shall be drilled with an electric drill. The doors
assembled as shown on drawings shall be placed in correct final position in the opening and marks made on
concrete members at jambs, sills and heads against the holes provided in frames for anchoring. The frame
shall then be removed from the opening and laid aside. Neat hole with parallel sides of appropriate size shall
then be drilled in the concrete members with an electric drill at the marking to house the expansion bolts. The
expansion bolts shall then be inserted in the holes, struck with a light hammer till the nuts are forced into the
anchor shell. The frame shall then be placed in final position. The frame shall be set in the opening by using
wooden wedges at supports and be plumbed in position.
Machining and Fitting:-
All wooden doors shall be machined by the manufacturer for cutouts, hinges, locks and all hardware requiring
routing and mortising. Any required rebating to properly hang doors will be performed by the manufacturer
prior to finishing. Finishing should be done by approved laminate on both sides. Doors shall be sized to allow
1/8” clearance at top and each side, and ¾” at bottom (unless specified otherwise.)
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FORMATE ID:
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REV NO.: 00
S.A.S. EFFECTIVE DATE:
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METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 334 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
Installation of Hardware:-
A. Contractor shall install hardware according to approved hardware schedule for proper locations.
B. Install with full-threaded wood screws furnished by hardware manufacturer.
C. Drill proper size pilot hole for all screws. (Full mortise hinges require 5/32” pilot holes.)
D. Securely anchor hardware in correct position and alignment.
E. Adjust hardware and door for proper function and smooth operation, proper latching, without force or
Excessive clearance.
Do’s:
Painting recommended to avoid any decay of wooden surface comes in contact with masonry or concrete.
1. Before taking for fabrication of wooden frames check the material thoroughly for any decay ,more no of
knots, cracks etc.
2. Stack the material in dry place to avoid moisture contamination.
3. Check the solid core ply shutter as per specification and thickness mentioned in drawing.
4. Always check laminate as per approved make and shade with no cuts on edges or any scratches on surfaces.
5. Adequate ventilation of the work area without causing the entry of Contaminants to other parts of the
building. Persons sensitive to odour and chemicals should avoid the area during installation.
6. Wear safety glasses to minimize the risk of eye injury.
7. Use a sharp and proper tools insure clean cuts. When not in use, store properly.
Don’ts:
1. Never install bend frames in position to avoid uneasy operation of doors.
2. Do not allow any cuts after final laminate finishing.
3. Do not use the material which is not specified for the sae.
4. Do not use the hardware mentioned below the required standard.
6.Inspection Record:
a. Checklist For joinery work
7.Inspection Test Plan :
b. Teak wood door frame, solid core plywood shutter
Records :
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METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 335 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
METHOD STATEMENT FOR
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Page 336 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
FINISHING SLAB CONCRETING USING
NON-METALLIC FLOOR HARDNER
& POWER TROWEL MACHINE
SR. EFFECTIVE REV. MSS MANAGER MSS PROJECT CLIENT
CLIENT QA/QC
NO. DATE NO. QA/QC MANAGER SUPERVISOR
FINISHING SLAB CONCRETING USING NON-METALLIC FLOOR HARDNER
&
POWER TROWEL MACHINE
1. INTRODUCTION
This document describes L&T methodology for the finishing of concrete with using floor hardener & power trowel
machine. To meet technical requirements, suitable construction methodology has been adopted in all the works to
ensure quality and safety apart from the speedy construction. A commitment to maintain the highest possible
standards has played a key role in finalizing the construction methodology for the finishing of concrete with
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NAME:
power trowel for Podium slab.
Scope: Scope of the work includes finishing of concrete with floor hardener & power trowel ..
2. REFERENCE
Following documents / drawing / codes have been referred for the preparation of this method statement:
a. Civil Structural Specification
b. Structural & Architectural drawing of all podium floor slabs.
3. Brief Methodology
The major construction activities for the concreting of Podium floor slab are as follows:
a. Concreting of Podium Slab
b. Application of Floor Hardener
c. Finishing with Power float
a. Concreting of Podium Slab
Concreting of Podium slab shall be same as per the method Statement No. --- & de-shuttering sequence.
b. Application of floor Hardener
Approved brand either of (BASF/ SIKA / SWC/ PIDILITE/ SUNANDA) Floor Hardener shall be used for all podium
slabs. After laying & compaction of concrete floor hardener of approved brand shall be uniformly applied as per
the recommended dosage of material over the green concrete. It is ideally applied to a surface, which is neither
too wet nor dry. Recommended time is 30-40 minutes, after the base concrete has harden enough to leaves light
foot prints of about 3-6 mm concrete should have a wet sheen. It shall be necessary to work progressively behind
the laying team to ensure application at the correct time.
c. Finishing with floor hardener & Power Float :
Floor hardener shall be applied at a recommended rate on to the concrete surface.
When the material becomes uniformly dark by the absorption of moisture from the base concrete, this
application shall be floated with the help of power floater.
Final finish of the floors can be done with a power float when the concrete has sufficiently stiffened to with
stand the mechanical force
4. Quantity:
For heavy duty – 05 Kg. per Sq. meter is recommended dosages.
Records :
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Page 338 of 864
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CONTRACTOR
NAME:
METHOD STATEMENT
FOR
BREAKING EXCESS CONCRETE
SR. EFFECTIVE REV. MSS MANAGER MSS PROJECT CLIENT
CLIENT QA/QC
NO. DATE NO. QA/QC MANAGER SUPERVISOR
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NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
BREAKING EXCESS CONCRETE
1. INTRODUCTION
This document describes L&T construction methodology for the breaking excess concrete. To
meet technical requirements, suitable construction methodology has been adopted in all the
works to ensure quality and safety apart from the speedy construction. A commitment to
maintain the highest possible standards has played a key role in finalizing the task.
2. Scope :
Scope of the work includes breaking excess concrete.
3. Specialised Equipment’s required:
- Spirit level, Concrete breaker of HILTI, level marking etc.
4. Brief Methodology:
a. Marking an area which has excess concrete as per the drawing (verified by QC engineer /
Architect in case of opening.
b. Making all arrangements of skilled labour and safety requirements.
c. Connecting electricity power to the HILTI – TE – 1000 AVR – concrete breaker for the
concrete of M60 / M40 grade.
d. Holding breaker at 45o starting from the top by using concrete breaker on marked line.
e. Taking care that there should not be heavy vibration to the connecting part of the structure
whose breaking is in progress.
f. After cutting up to bottom of marking line, Concrete debris after cutting shall be disposed off
properly.
Records :
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MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
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DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 340 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
METHOD STATEMENT FOR
HONEYCOMB CONTROL &
PREVENTION IN CONCRETE SURFACE
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TITLE:
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Page 341 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
SR. EFFECTIVE REV. MSS MANAGER MSS PROJECT CLIENT
CLIENT QA/QC
NO. DATE NO. QA/QC MANAGER SUPERVISOR
HONEYCOMB CONTROL & PREVENTION IN CONCRETE SURFACE
1. INTRODUCTION
This document describes L&T methodology for the honey comb control & prevention on the
concrete surface. The nature of the project and the schedule duration are challenging. To meet
technical requirements, suitable construction methodology has been adopted in all the works to
ensure quality and safety apart from the speedy construction. A commitment to maintain the
highest possible standards has played a key role in finalizing the construction methodology
for the construction of ground floor slab.
2. Scope :
Scope of the work includes control & prevention of honey combs in concrete surface.
3. REFERENCE
Following documents / drawing / codes have been referred for the preparation of this method
statement:
D. Civil Structural Specification
E. Structural & Architectural drawing of ground floor slab
4. EQUIPMENTS:
a. Paint brush, Trowel, Float, Hand chisel, hammer, wire brush, Mortar pan etc.
b. Grouting material (Non shrink grout materials), RANROC RG or GP-2 (Fosroc make) or equivalent.
5. Methodology
5.1.1 Controlling of Honey comb
5.1.2 Prevention of Honeycomb
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5.1.3 Rectification of Honeycomb
5.1.1 Controlling of honeycomb:
a. Before any concrete pour sufficient nos. needle vibrators & high frequency needle will be
deployed up-to the end of concrete pour.
b. Manual compaction with wooden mallet at the rate of one person per 1.5 meter running
length of structural member will be deployed for compaction at the bottom portion of the
structural member case of column and walls.
5.1.2 Prevention of honeycomb:
a. Mix shall be cohesive and rectify accordingly
b. In case of dense reinforcement proper methods like chute, funnel shall be used.
c. Proper placing arrangement to be made for concreting.
5.1.3 Type of honeycomb:
i. Minor Honey comb
ii. Medium Honeycomb
iii. Major Honeycomb
5.2: Surface Preparation:
a. Remove all porous, honeycombed and unsound or defective concrete by chipping.
b. Keep the surface properly wet before starting the repair.
C. Clean the holes to remove chipping dust, and other foreign materials.
d. Wash the surface thoroughly after trimming and cleaning.
5.3: Rectification of honeycomb ( in brief ):
Following methods are used rectification of honeycomb
5.3.1: Method I for minor Honeycomb
5.3.2: Method II for Medium Honeycomb
5.3.3: Method III for Major Honeycomb
5.3.1.: Procedure for Method I :
a. Prepare a dry pack mix of one part of cement and two parts of sand with only enough water to
produce a mortar which will stick together on being moulded into a ball by slight pressure of the
hands.
b. Pack the dry pack material in the repairing place, should be placed and packed well compacted.
c. Use trowel to finish the repaired surface to improve the appearance & Cure the surface in the usual
way.
5.3.2: Method II:
a. It shall be treated with GP1 / GP 2 “material manufactured by FOSROC Chemicals as per the data
sheet enclosed.
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b. Mixing above mentioned special mortar for at least 05 minutes with required amount of water
required to attain dough like consistency so that it can be hand packed.
c. This special mortar is to be packed with trowel in the honeycombed concrete. Ramming will be
done & finished with trowel to match existing concrete surface.
d. Wet curing will be done for 7 days on the treated surface.
5.3.3: Method III:
a. It shall be treated with “POLYALK –EP “material manufactured by Sunanda Chemicals as per the
data sheet enclosed. (Mix of 1 Kg. of POLYALK EP, ready to use).
b. Mixing above mentioned special mortar for at least 03minutes with required amount of water
required to attain dough like consistency so that it can be hand packed.
c. This special mortar is to be hand packed in the honeycombed concrete. Ramming will be done
by wooden mallet & finished with trowel to match existing concrete surface.
d. Wet curing will be done for 7 days on the treated surface
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NAME:
METHOD STATEMENT FOR
HONEYCOMB/ VOID RECTIFICATION IN
CONCRETE SURFACE
SR. EFFECTIVE REV. MSS MANAGER MSS PROJECT CLIENT
CLIENT QA/QC
NO. DATE NO. QA/QC MANAGER SUPERVISOR
HONEYCOMB/ VOID RECTIFICATION IN CONCRETE SURFACE
1. SCOPE
This document describes construction methodology for the honey comb control & prevention on the
concrete surface &VOID filling To meet technical requirements, suitable construction methodology has been
adopted in all the works to ensure quality and safety apart from the speedy construction.
2. Reference Documents
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Following documents / drawing / codes have been referred for the preparation of this method statement:
1. Civil Structural Specification
2. Structural & Architectural drawing of Mould Element
3. Technical Data sheet of all specialised material
3. EQUIPMENTS &MATERIALS :
a. Paint brush, Trowel, Float, Hand chisel, hammer, wire brush, Mortar pan etc.
b. Bonding Agents like Nito Bond EP/EMACCO BONDING / SIKADUR 32LP.
c. Micro Concrete Material like RENDROC HS EXTRA /SIKA REP MICROCRETE-04/EMACO S66T.
d. Minor Rectification material (Non shrink materials), RANROC RG or GP-2 (Fosroc make), Poly
expanse (Sunanda make) or equivalent.
e. Crack Fill Material like Rendroc FC / SIKA CRACK SIL / EMMACO R307.
4. SURFACE PREPARATION.
For any type of repair the surface must be prepared before applying the repair material. Whatever the repair
method that is adopted the first step is the surface must be sound and thoroughly cleaned. All loose particles
and mortar laitance, dirt, paint, etc. must be removed by brushing with stiff wire brush or other suitable
means until sound material is completely expose. This will ensure a bond between the bonding agent and the
structure. Repair shall be applied directly to the original surface. In case steel is exposed, all exposed
reinforcement should be thoroughly cleaned of any loose rust, scales or any contamination that might
interfere with bond. Steel has to be cleaned with no signs of rust. This initial preparation is vitally important
and no reinstatement should be permitted unless it has been done.
5. CLASSIFICATION OF REPAIR :
Repair may be broadly classified in the following categories:
A. Repair of spelled / chipped edges and corner.
B. Closing of lifting pockets / recesses/ void, spelled edges 100 mm or more.
C. Hair line crack with width of 0.25mm or less.
D. Hair line crack with width of 0.25mm or more.
E. Fixing of new dowel (missing or relocation.)
F. Convex or concave bowing larger than I.S. standard.
( Note: For A & B requires repair procedure no. 1, For C & D requires repair procedure no. 2, For E
requires repair procedure no. 3, For F requires repair procedure no. 4 )
REPAIR PROCEDURE NO. 1 (A)
NON- EXPOSED TEXTURE GREY CONCRETE REPAIR TO SPALLED / CHIPPED EDGES AND CORNERS RANGE 0 TO
50MM
1. Remove chipped and loose concrete.
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2. Saturate with water and apply Nito Bond EP/EMACCO BONDING / SIKADUR 32LP or equivalent agent
solution.
3. Apply RENDROC HS EXTRA /SIKA REP MICROCRETE-04/EMACO S66T or equivalent.
4. After ONE day curing it will be finished with mortar having cement & fly ash.
CLOSING OF LIFTING POCKETS / RECESSESSPALLED EDGES 50MM OR MORE
1. All unsound material, paint, dust and loose particles shall be removed.
2. The prepared area shall be thoroughly wet with clean water before start of repair works.
3. Nito bond EP s or equivalent hall be applied to the repair surface (Solution 3).
4. Apply RENDEROC RG / MASTERFLOW or equivalent on the surface.
5. After one day curing it will be finished with mortar having cement & fly ash.
REPAIR PROCEDURE No. 1 (B)
For (white concrete) SPALLED EDGES Etc.
Micro Concrete mixture as per approved modified in terms of workability and bonding agent as necessary in order
to improve the repair.
MORTAR AGGREGATE MIXTURE
One part white cement to 2 parts white sand and containing Non shrink bonding agent as necessary in order to
improve the repair. Aggregate powder will be use to match the color of the panel. Workability to be appropriate to
the type of repair required and aggregate added as appropriate. All materials to be as indicated in approved mix
design. Lifting pockets / recesses and larger repairs are to be effective using approved mix design delivered from
factory. THE AGGREGATE TO BE USE IN THE SURFACE FINISH WILL BE SAND BLASTED. Aggregate powder will be
added to match the color of the repair portion.
Small repair may be effective by placing the patching mortar and embedding sand blasted aggregate as necessary
to closely reproduce the existing texture of the surrounding concrete.
After placing the patching material, it will be formed to the required contour of the panel and carefully feathered
out using appropriate tools to effect adequate blending of the patch to the parent concrete.
After initial hardening of the patch, it shall be slightly rub by plastic brush to expose the aggregate as necessary in
order to re – create the parent concrete finish and texture as closely as practically possible.
NOTE: For mixing of bonding agent solution - As per manufacturers specification.
REPAIR PROCEDURE No. 2
FOR CRACKED PANELS
A. HAIRLINE CRACK WITH WIDTH 0.25MM OR LESS
1. All area to be repaired shall be marked out.
2. The entire length of the crack to be notched out “V” shape at about 3mm deep.
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3. Saturate with water and apply bonding agent solution (3).
4. Apply and finish by renderoc FC / SIKA CRACK SIL / EMMACO R307 or equivalent.
B. HAIRLINE CRACK WITH WIDTH 0.25MM OR MORE
1. All area to be repaired shall be marked out.
2. The entire length of the crack to be notched out “V” shape at about 6mm deep.
3. Apply and finish by Renderoc FC or equivalent.
REPAIR PROCEDURE No. 3
FIXING OF NEW DOWELS (MISSING OR RELOCATION)
MISSING / MISLOCATION OF DOWELS (materials to be used)
1. Lock set S80 (FOSROC) / Re100 (HILTI) or equivalent.
2. Dowel bars.
PROCEDURE:
1. Drill a hole with the required Length & diameter size as per Manufacturer’s recommendations.
2. Clean out the hole with hand pump or electric blower.
3. Pour in approved chemicals.
4. Push the threaded bar or dowel bar in and allow it to attain required strength before using.
REPAIR PROCEDURE NO. 4
STRAIGHTNESS OR BOW
1. Convex Bowing (Projecting surface is more than required) Preparation and repair
A) All the area to be repaired shall be marked out.
B) Cup wheel grinding machine to be used to level the bulged portion in the surface.
C) Saturate with water and apply bonding agent solution (3).
D) Apply and finish by Rendroc FC or equivalent.
2. Concave Bowing (Depress from the required surface) Preparation and repair
A) All areas to be repaired shall be marked out.
B) Saturate with water and apply bonding agent solution (3).
C) Apply Rendroc FC or equivalent up to 3mm thick.
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METHOD STATEMENT
FOR
GLASS PARTITION WORKS
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SR. EFFECTIVE REV. MSS MANAGER MSS PROJECT CLIENT
CLIENT QA/QC
NO. DATE NO. QA/QC MANAGER SUPERVISOR
GLASS PARTITION WORKS
1. Objective:
This work procedure enumerates the scope of Glass partition work to be executed in the superstructures of
different buildings as a partition for cabins, meeting rooms and conference rooms with gypsum partition or
without gypsum partition. & as specified in the approved drawings and at places when instructed by the
Engineer-in-charge as per approved specifications.
2. Applicability:
This procedure is applicable to the Glass partition work for Main Building.
3. Reference Document:
Tender Specifications
Drawings
Manufacturer’s Guidelines
Indian & International Standard
4. Equipment’s:
Safety Glasses, Measuring Rule, Straight Edge, Rubber Hammer, Pencil, 2" or 3'Carpenter's Level ,Water Level,
Mini angle grinder, Mini drill machine, aluminum cutting machine, cutting players , screw drivers, Line, Chalk,
Rubber gasket, Baker rod, glass sealant, masking tape, Glass vacuum lifter, MS supporting box section and
Anchor Fasteners.
5. Procedure:
a. Preparatory works:
Panels are of glass, fastened to top and The support rails are of anodized aluminum.
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1. Furnish and install glass partitions and Provide all labor, materials, tools, equipment, and services for
glass walls in accordance with provisions of contract documents.
1.01 RELATED WORK BY OTHERS
A. Preparation of opening will be in gypsum partition providing fins as per approved drawings. Any
deviation of site conditions contrary to approved shop drawings must be called to the attention of the
architect.
B. All headers, blocking, support structures, jambs, and track enclosures, as required as per
specifications.
C. Paint or otherwise finishing all trim and other materials adjoining head and jamb of the partitions.
b. Material
1. Glass panels shall be 12mm thick and to specified in width.
2. Glass shall be attached to top and bottom rails.
3. All glass edges shall be polished and glass panel shall be toughened glass as per specifications
4. Top and bottom horizontal rail shall be anodized aluminum and Incorporate light seals.
5. Glass faces shall have no vertical trim. (Important note: there is a maximum 2mm gap between
panel joints to prevent glass from touching during panel setup. Size of gap varies due to glass
tolerances and should be filled with clear silicon to prevent sound travelling in and out.
c. Installing glass partition
1. Measure the exact location of the door openings and mark it on floors.
2. Do the gypsum partition framing as per approved drawings.
3. Wherever door fins an opening are there insert 50mmx50mm size teak wood section inside G.I. stud
member.
4. Where glass panel is coming insert the 50mmx50mm size teak wood member at top and that is
supported with 25mmx25mm M.S. box section with anchor fastener to the true ceiling.
5. This MS support will provide rigidity to glass partition
6. Door frame and wooden leaping is fixed at position prior to install glass. That should be properly
finished as per specifications (especially sides, top and jambs.)
7. Fix top and bottom aluminium rails with respect to line level and plumb.
8. Insert toughened glass panel in bottom rail first and push slightly to fit in top rail by using glass
vacuum lifter.
9. Fix the other side of leaping only after glass installation and finish it properly.
10. Do cross mark on the glass by masking tape to avoid hitting it by any object or workmen
11. Fill clear silicon at joints and at top and bottom rails.
d. Do’s:
1. Painting recommended at sides where glass is to be fitted.
2. Stacking of glass should be vertical in the proper behind support.
3. Glass should be handled carefully to protect the face and edges from damage.
4. Adequate ventilation of the work area without causing the entry of contaminants to other parts of
the building. Persons sensitive to odour and chemicals should avoid the area during installation.
5. Wear safety glasses to minimize the risk of eye injury.
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e. Don’ts:
1. Do not leave gap between to glass panels more than specified
2. Never install glass before all preparatory works completed.
3. Never stack the glasses touching each other.
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METHOD STATEMENT
FOR
DOOR FRAMES & SHUTTERS
SR. EFFECTIVE REV. MSS MANAGER MSS PROJECT CLIENT
CLIENT QA/QC
NO. DATE NO. QA/QC MANAGER SUPERVISOR
Frames for Doors / Windows / Openings
Raw Materials:
A) Wooden Doors / window frames:
1) Door frames shall be checked for uniformity in thickness, right angles from inside surface, straightness &
warpage of members, if any.
2) Three exposed surfaces of frame shall be checked for smooth planning.
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3) All door frames shall be provided with knee braces and bottom patti. Also joinery and filling of joints shall be
satisfactory. Frame shall be machine papered and have satisfactory finish.
4) Depth of rebate should be as per recommendation of Architect (Depth of rebate in door-frame ideally shall be
minimum 15 mm and in window /ventilator frames shall be minimum 12 mm). Rebates shall be uniform through
the length of frame.
5) Thickness of tenon shall be 1/3 rd that of member and width of tenon shall not exceed five times the
thickness. Horns shall project 50/100 mm. As far as possible horns should be avoided.
6) Door frames shall be provided with minimum 3 nos. of holdfasts on either side. Holdfast being made of MS
flats 25 mm. wide, 230 mm long and 2 mm thick. Ends of the hold fasts shall be split. One holdfast shall be
provided at centre whereas other two shall be provided at 30 cms from top and bottom ends of the frame. For
main door, minimum 4 nos. of holdfast should be provided.
7) All door frames shall be applied with primer (for paint) and multan matti (for polish) immediately after their
receipt at site.
B) Natural stone door frames:
1) Vertical as well as horizontal members shall be in one piece, without cracks or flaws.
2) Rebates shall be recommended same as of wooden door frames. Polish within the rebate shall be same as that
for the rest of frame.
3) Location /diameter of holes for fixing Aldrops/ Tadipattis shall be as per drawings.
4) Rounding done shall be smooth with proper finish.
C) Frames for openings (wooden):
1) Wooden sections shall be as per recommendation of Architect and of full size. (Minimum required section size
ideally shall be 4” X 2.5” for opening size up to 1 mtr. and 5” X 2.5” for opening size greater than 1 meter up to 2
meter).
2) Wood shall be fully seasoned, crack free and straight.
3) Wood shall have parallel grain structure and the surface should be dry and without oily secretions.
4) Moisture content in wood shall not exceed 14 % when checked with moisture meter.
5) Single section shall not have more than 3 knots.
Procedures for Fixing of Frames and Shutters:
Frames for doors/ windows/ openings
a) Pre fixing procedures:
1) Necessary architectural drawing showing details of doors, windows and openings shall be available on site.
2) Door frames which are found to be out of plumb shall be planed properly to bring it into plumb.
3) Bottom portion of vertical members of frame shall be marked with paint, indicating level up to which they are
to be embedded in the floor bedding .This shall be achieved by taking floor tilling level pads.
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4) Portion of door frame to be embedded in floor as well as face of the frame in the contact with masonry shall
be applied with two coats of a bituminous paint (Black Japan or equivalent) and remaining sides @ bottom 6” (6”
from slab level) shall be applied with transparent protective coat (wood guard).
5) Bottom portion of vertical members of frame shall be provided with metal pin for proper anchorage in to the
floor bedding.
6) Application of one coat of wood primer / multan matti shall be ensured on all frames before erection.
7) Opening shall be finished to correct dimensions, level, plumb and diagonals.
8) If opening sizes are found smaller than required, the same shall be brought to correct dimensions by
roughening the surface and finishing by plastering neatly in line and level.
9) If opening sizes are found larger than required, the same shall be chipped off using round wheel cutter and
chisel. Undulations shall then be finished by plastering neatly in line and level .
b) During fixing procedure:
Door /window frames:
1) Door frames shall be fixed along with masonry work, with level of frames matching with level pads of finished
plaster level. Window frames shall be fixed after completion of internal plaster.
2) If bends are observed in the frames, wedges shall be inserted between frames and masonry surface to remove
bends.
3) Holdfast shall be embedded in masonry with M-15concrete.
4) Holdfast, if required to be fixed to concrete surface viz. column, then they should be fixed by drilling holes in
concrete. Nailing in concrete shall be avoided. Coach screw can be used for the same. Coach screw of approved
cross section and length sunk within the frame and capped by plugging with the same timber material.
5) Knee braces for frames shall not be removed unless frame is fixed satisfactorily.
6) If natural stone frames are required to be fixed over plastered surface, then the plastered surface shall be
roughened adequately. Sand faced plaster shall be hacked, whereas neeru / sanla surface shall be grinded.
7) Coat of epoxy with marble chips / sand shall be applied at the back of natural stone frame, at least one day
prior to frame fixing.
8) In case of natural stone frames, vertical and horizontal frame members shall be joined with neatly finished hair
line joints. White cement shall be used in case of marble frames where as gray cement shall be used in case of
granite stone frames.
Frames for opening:
1) Section shall be cut to required size, and planed perfectly to remove any bends along the length of sections.
2) Offsets for shutters shall be machine cut and planned to have a perfect straight cut as per requirement.
3) Holdfast shall be of MS / GI 3mm thick and coated with red oxide.
c) Post fixing procedures
Door / window / opening frames
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 355 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
1) After fixing of frame, the entire frame shall be again checked for plumb, level, right angle and necessary
rectification shall be carried out if required.
2) Cover moulding should be provided at the junction of plaster surface and wooden frame.
Shutters for Doors
Wooden flush – Solid core
1) Door shutter brand shall be checked for approved make as per specification.
2) The type of shutter, thickness and surface finish on both sides as well as other dimensions of shutters shall be
checked for correctness as per requirement.
3) Moisture content in the wood shall be checked by moisture meter, and moisture content within the wood
shall not exceed 12% asper IS 2202(Part1):1999
4) Timber used for door shutters shall be well seasoned and without any cracks.
5) Knots, if presents, shall not be more than 3 per shutter.
6) Shutters with bends at corners shall be rejected.
7) Immediately after receipt, door shutters shall be applied with wood primer on all sides including edges, except
decorative veneer surface.
Other Accessories
a) Lipping Patti:
Lipping Patti shall be in teak wood and in one piece. Double lipping Patti shall not be used to increase the door
shutter size.
b) Primer:
Primer to be applied to door shutters shall be as per recommendation of paint manufacturer/ as specified by
Architect.
c) Putty:
Multan matti shall be used as primer; otherwise putty shall be made by mixing whitening powder with linseed oil
with approved brand and manufacturer’s specification.
d) Bitumen paint:
Anticorrosive paint shall be bituminous, black Japan is preferable.
e) Door accessories:
1) Door accessories like Aldrops, Tadipattis, Tower Bolts, Door handles, Hinges and stoppers shall be as per
Architect’s specifications.
2) Sizes shall match with those indicated on drawings.
3) Hinges of brass or stainless steel are recommended.
4) Accessories shall be chosen at random for checking of proper functionality.
Test on door shutters:
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MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
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TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 356 of 864
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A) Dimensional checks (non destructive test):
Measurement of length and width,
Measurement of Thickness,
Square ness,
Twist.
B) Steel ball impact test,
C) Destructive tests:
End emersion test,
Glue adhesive test,
Knife test.
In additional to above, following tests shall be carried out in laboratory for wood and door shutters, conforming
to IS 2202(Part 1):1999
Varying humidity test,
Slamming test,
General flatness test,
Shock resistance test,
Edge loading test,
Local plainness test,
Flexural test,
Bulking test,
Screw pull out test.
Procedures
a) Pre Fixing Procedures for door shutters.
1) If required, Lipping Patti shall be provided on shutter. Lipping Patti shall be of teak - wood and in one piece.
Joint shall be provided only at corners.
2) Primer and one coat of specified paint as specified by Architect shall be applied to all sides of shutter including
lipping patti before fixing any fitting on shutter.
b) During fixing procedures for door shutters
1) Type and size of hinges shall be depending upon weight, thickness and type of opening of shutter as specified
by Architect.
2) Number of hinges shall be minimum 4 nos. for main door. Position of hinges shall be 1st at top, 2nd at 600 mm
from top, 3rd at centre and 4th at bottom or equidistant or specified by Architect.
3) Screws in hinges shall be driven with the help of screw driver and not hammered.
4) Care shall be taken to see to it, that automatic door closer, if fixed to the door shall not touch the wall, during
operation.
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5) Door shutter shall be fixed in such a way that, uniform gap of 3 mm. is maintained between door frame and
door shutter on a top as well as sides. Also 5 mm. gap shall be maintained between bottom of shutter and
Finished Floor Level (FFL).
6) PVC Sheet shall be fixed with suitable adhesive to either side of door shutter for doors in toilet and terrace if
specified by Architect.
7) All other door accessories like Aldrops, tadipatties, tower bolts, door handles, hinges; eye piece, magnetic door
stopper and latch shall then be fixed as per drawing at specified positions.
8) Checking of latch and guidelines should be followed as per manufacturer’s specifications for its position and its
fixing.
c) Post fixing procedures for door shutters
After fixing of door shutter at least one Aldrops shall be fixed from outside for locking the door.
Acceptance of Completed Work
Doors / Windows /Openings Frames and Door Shutters.
Type of Check Acceptance
Tests for wood satisfactory Accepted
Tests for door shutters satisfactory Accepted
Holdfasts for frames as specified As per recommendation
Hold fasts for door shutters as specified As per recommendation
Fixing of hold fast as specified As per recommendation
Door frame in plumb Accepted
Door shutter in plumb Accepted
Size and no. of hinges provided As per recommendation
Antirust screws provided in hinges Accepted
Screws not hammered inside hinges Accepted
Lipping patti in one piece Accepted
Gaps between door shutter and frame 3 mm. uniform
Gaps between door shutter and FFL 5 mm. uniform
Operation of night latch and other accessories Smooth
Records :
Reference Documents :
ITP Reference No :
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METHOD STATEMENT FOR
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Page 359 of 864
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MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
SANITARY WARES, FITTINGS &
ACCESSORIES INSTALLATION
SR. EFFECTIVE REV. MSS MANAGER MSS PROJECT CLIENT
CLIENT QA/QC
NO. DATE NO. QA/QC MANAGER SUPERVISOR
INSTALLATION SANITARY WARES, FITTINGS & ACCESSORIES
1. PURPOSE
The method statement of sanitary wares, fittings & accessories installation describes the method of
supply and installation works executed in a safe manner and in accordance with the project requirements.
All quality assurance/control activities are carried out in a systematic manner where works are inspected
to specified conformance which will be verified and documented for the project.
2. REFERENCES
This method statement is subject to the requirements as stated in the following regulatory & statutory
documents, applicable standards, specifications, and building codes:
Project Specification – Plumbing Fixtures (Water Closet/Bidet/Hand Wash Basins/Sinks/Bath
Tubs/Hand Spray/Shower Sets/Floor Drains)
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NAME:
Relevant Sections of IPC
Project approved IFC drawings & materials
Approved HSE Plan
3. Sanitary wares, fittings & accessories installation
Storage of Materials
Loading and unloading of delivered plumbing fixtures and accessories and relevant materials shall be
carried out manually or mechanically.
Handling to be strict as per manufacturer’s recommendation and as necessary, in a protective packing,
crating, and covering. Retain the original protection by the manufacturer until the area for installation is
ready.
On the receipt of material, a visual check will be made to ensure that the components comply with the
approved schedules, packing list, and installation drawings.
The shifting activity to be planned.
Store sanitary fixtures on elevated platforms in a dry location.
If plumbing fixtures and accessories are not to be installed immediately after the delivery at site, store
plumbing fixtures on elevated platforms and dry location without hindering the safety of the personnel.
The storage area to be identified
All the equipment & accessories that will be transported on the site will be inspected thoroughly and
travel on the specified routes of the contractor and unload on the specified place near the workplace.
Extra precautions will be implemented during transporting all materials and equipment and carefully
following all the traffic signs while inside the project site.
4. Preparation
Verify if the area for installation is ready & works related to other disciplines are completed prior to
starting the installation.
Inform in advance to the responsible person if any foreseen problem occurs.
Examine roughing-in for potable, hot- and cold water supply piping systems; soil, waste, and vent piping
systems; and supports. Verify that locations and sizes of piping and locations and types of supports match
those indicated, before installing and connecting fixtures. Use manufacturer’s roughing-in data when
roughing-in data are not indicated.
Examine walls, floors, and cabinets for suitable conditions where fixtures are to be installed.
Do not proceed until unsatisfactory conditions have been corrected.
5. Installation of Plumbing Fixtures
Assemble plumbing fixtures and trim, fittings, faucets, and other components according to
manufacturers’ written instructions.
Install fixtures level and plumb according to manufacturers’ written instructions, roughing-in drawings,
approved architectural layouts, and referenced standards.
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Install wall-hanging, back-outlet water closets with support manufacturer’s tiling frame or setting gage.
Install toilet seats on water closets as specified
6. Install wall-hanging, back-outlet urinals with gasket seals
Fasten wall-hanging plumbing fixtures securely to supports attached to building substrate when
supports are specified, and to building wall construction where no support is indicated.
Fasten floor-mounted fixtures to substrate. Fasten fixtures having holes for securing fixture to wall
construction, to reinforcement built into walls.
Fasten recessed, wall-mounted fittings to reinforcement built into walls.
Fasten wall-mounted fittings to reinforcement built into walls.
Fasten counter-mounting plumbing fixtures to casework.
Secure supplies to supports or substrate within pipe space behind the fixture.
Set shower receptors and mop basins in leveling bed of cement grout.
Install individual stop valve in each water supply to fixture. Use gate or globe valve where a specific
stop valve is not specified. Omit stop valves on supplies to emergency equipment
Install water-supply stop valves inaccessible locations.
Install faucet laminar-flow fittings with specified flow rates and patterns in faucet spouts when faucets
are not available with required rates and patterns. Include adapters when required.
Install shower, flow-control fittings with specified maximum flow rates in shower arms.
Install traps on fixture outlets. Omit traps on fixtures having integral traps. Omit traps on indirect
wastes, except where otherwise indicated.
Install disposers in sink outlets. Install switch where indicated, or in-wall adjacent to sink if the location
is not indicated.
Install escutcheons at the wall, floor, and ceiling penetrations in exposed, finished locations and within
cabinets. Use deep-pattern escutcheons were required to conceal protruding pipe fittings.
Seal joints between fixtures and walls, floors, and counters using sanitary-type silicone sealant
according to sealing requirements specified by the manufacturer.
The location, elevation, orientation, and type of fixtures shall be as per approved architectural layouts,
Materials submittals & manufacturer’s datasheets.
7. Connections
Drawings indicate the general arrangement of piping, fittings, and specialties. The following are
specific connection requirements:
Install piping connections between plumbing fixtures and piping systems and plumbing equipment
specified in the approved shop drawings/details
Supply and Waste Connections to Plumbing Fixtures:
Refer to product sheets/detail drawings for fitting sizes and connection requirements for each
plumbing fixture.
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Supply and Waste Connections to Equipment Specified in Other Sections:
Connect equipment with supply inlets, supply stops, supply risers, and traps specified in product data
sheets/detail drawings. Use fitting sizes required to match connected equipment. Connect fittings to
plumbing piping.
8. Manpower Requirement
Subject to main contractors program and scope/area available for MEP activities, but not limited to
below:
Chargehands
Plumbers
Helpers
9. Material Requirement
Ensure material being used are of approved manufacturer/material submittal from project vendor list
and of quality as specified.
Approved type & make of sanitary ware fixture & fittings, approved carriers for fixtures recommended
type of sealant, etc.
10.Tools & Equipment
Platform ladder
Step ladder
Hand Tools (Hammer, wrenches, L-Key set)
Spirit Level
Battery operated hand drilling machine
Hammer Drilling Machine
Sealant Gun
Spanner set box
Allen key set
Palletizer Jack
Records :
Reference Documents :
ITP Reference No :
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METHOD STATEMENT
FOR
METAL DOOR INSTALLATION
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TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 364 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
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CONTRACTOR
NAME:
SR. EFFECTIVE REV. MSS MANAGER MSS PROJECT CLIENT
CLIENT QA/QC
NO. DATE NO. QA/QC MANAGER SUPERVISOR
METAL DOOR INSTALLATION
1. Purpose
This Method Statement of Metal Door defines the installation process, quality control, and safety
requirements, as well as the equipment to be used to perform the tasks according to the project
specifications.
2. Scope
Its scope specified in the method statement can be used for the installation of metal frames and doors.
4. References
Standards-Steel Door Institute 117 (SDI 117)
5. Tools and Equipment
Drill machine
Concrete drill bits
Level
Flathead plastic hammer
Flathead screwdriver
Star head screwdriver
Measuring tape
Ladder
Boom Loader/Crane
6. Methodology-Method Statement of Metal Door Installation
6.a Site storage and handling of material
Information prior to storage on-site:
Door frames and leaves are manufactured and powder coated according to the color that is approved
by the project.
They are not required to be repainted or require additional coatings or touch-ups at the site unless
they are damaged after the delivery of the materials.
Thus, extreme care has to be taken to preserve the color and evenness of the coating at every stage of
the life cycle of the materials.
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The materials are put inside a truck or container in a manner that door leaves are securely wrapped
with stretch-wraps, and then laid out on a pallet.
The door frames are wrapped in bubble wraps, and then put in order and are arranged freely.
The unloading of the steel doors and frames from the truck may be done either by manually unloading
or by using forklifts.
Make sure that the storage area is set up prior to the arrival of the materials, in order that the material
can be moved into the storage space without having to be temporarily stored in exposed areas, as the
latter could cause serious damage to the material.
6.b Additional care to be taken during storage:
As well as the previous considerations, the following precautions need to be observed when keeping
the materials on the construction site.
If a grouping of the materials is done, not more than 5 door leaves (or) frames that are
welded/assembled will be stored in a group.
Frames used to create multi-opening frames, must be stored in no more than three groups as a group
larger than that could cause severe harm to the frame at the bottom.
All welded (or) assembled frames must be stored in a proper place and laid down.
In storage, the door leaves and frames are to be kept from getting direct deposits of sand and dust to
prevent the formation of scratch marks on the surface coat.
Furthermore, if materials are to be cleaned/wiped they should only be cleaned with a soft, damp cloth
that is thoroughly rinsed to get rid of the dust that has eventually accumulated on them.
After which the materials shall be kept to dry-free and moisture-free air.
6.c Installation procedure at the site
Select the required door and frame from the site storage.
All the materials needed for the installation will be taken and delivered to the installation site along
with the delivery note.
The vehicle should be driven within the access zone designated after having obtained the necessary
permission from security.
Vehicles to be parked within the designated unloading area. Then the storage or stacking area must be
properly covered. The area facilities for storage/stacking will be provided.
The unloading of the materials should be completed with the aid of a boom-loader truck or forklift.
Materials Inspection Request (MIR) to be made immediately following the delivery of the material, and
prior to beginning the installation.
6.d Transfer of material to the door’s designated location
Based on the opening number, the installation team will segregate the frames, and doors at the
specified site.
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The installation crew will move the material to the location via designated pedestrian access or
egress. The crossing must be at only the specific crossing point.
The frame and door leaf shifting can be performed by two (2) installers in each specified area.
The transfer of each material will be in accordance with safety rules and safety programs.
7. Frame Installation
Frames to be installed will be carried out in accordance with the manufacturer’s specifications and SDI
standards. Grouting within the frame isn’t necessary.
The following steps must be followed:
7. a For Concrete Wall and Masonry Wall & Dry Wall Partition
The proper placement should be observed. Finish the floor with level markings and threshold, if
applicable should be confirmed before frame assembly.
It is important to get MEP clearance for wiring inside or conduits for card access systems or another
MEP device if any.
After the measurement of the site, the opening should be verified in accordance with the approved
shop drawing.
Make sure that all door frames are on the same wall or in the same space at the same height.
Ladders are not required for frames that are fixed above the floor’s finish level of 2.2m. However, if a
greater than 2.2m mobile scaffold is needed.
The frame installation tolerance – the distance between the door frame and wall should be verified.
In the event that the frame’s in the knockdown stage, which includes three components (header, strike
jamb, and the hinge jamb) the frame’s header and strike jamb are put together on the floor using the
corners clip and by connecting with the M5 screws. The assembly should match the approved mockup.
The frame that is assembled will be placed inside the door opening.
The header’s level and strike jamb must be level prior to fixing the expansion-type anchor bolt.
A hinge jamb should be put inside the head slot and the alignment will be verified prior to fixing the
expansion type anchor bolt.
A proper alignment of openings must be achieved.
Keep the frame in the opening and make sure that each anchor bolt is tightened.
Install the rubber gasket.
The proper protection of the door frame must be put in place to avoid any damage.
Proper protection for the frame and ironmongery of the door should be put in place when the leaf has
not been put in place in the meantime.
Threshold (if there is one) is possible to be added after the frame has been installed or door.
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8. Door Installation
The installation of doors is to be performed following the manufacturer’s specifications and SDI
standards. But, based on the style, dimensions, and weight of the door, the following steps are
described according to the following specifications:
8.a For doors up to height 2.2m and below:
Doors that are fixed above the floor’s finish, the floor up to 2.2m, ladders will not be required.
However, in the event that they extend beyond 2.2m small ladders are needed.
Two installers will be enough to support this weight (50 kilograms) of the door during its installation.
The leaves can be hung with just 8 screws to secure the hinges.
Door heights as high as 2.2m – 3 hinges are enough for a door leaf according to SDI standards.
Door heights greater than 2.2m – 4 number of hinges will be determined as per SDI standards.
When the entire door’s weight is placed on the hinges, close the hinges by putting them in order from
top and bottom and then the middle hinge.
Use all eight screws and make sure they are tight until they are flush on the hinge. The door’s hinges
will be hung on the frames in accordance with the number of hinges.
Make sure that SDI and industry tolerances of the frame and the door are ensured.
Install additional hardware e.g. locks or closers according to the manufacturer’s instructions for each,
SDI standard & project specifications.
Work Inspection Request (WIR) must be made at all stages in accordance with the Inspection and Test
Plan (ITP).
8.b For doors of height 2.2m and above with a weight of more than 100kg:
For any door that is fixed over the floor’s finishing line over 2.2m, a scaffold or a tower is required.
Four technicians assisted by the loader boom are needed to lift all the load (100 kilograms) that the
door needs during its installation.
Door height greater than 2.2m – 4 number of hinges should be supplied as per SDI standards and
approved shop drawings.
When the door’s weight is placed on the hinges, close the hinges to the point of a top and bottom and
then the middle one.
Use all eight screws and make sure they are tight until they are flush on the hinge. The door’s leaf is to
be hung on the frames that are attached to them with the number of hinges (preferably 5-6 hinges)
Make sure that SDI and Industry tolerances of the frame and the frame are ensured.
Install additional hardware e.g. locks or closers. according to the manufacturer’s instructions and SDI
specifications.
The Work Inspection request (WIR) must be made at all stages in accordance with the Inspection and
Test Plan (ITP).
8.c For Grill Doors – 150kg weight:
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The grill door installation is somewhat different from regular steel doors because of its shape, design,
and weight.
Using equipment similar to boom loaders and cranes – All lifting that is supported by belts must be
certified by a third party. A medium to heavy-duty forklift is required for the installation.
Six technicians will be required to help support this load (150 kg) using the lifting equipment used to
align the door during the installation.
There is one operator from the contractor who is operating on the boom loader and two individuals
balancing the door using a chain or belt. A proper PPE must be used.
This door will be a final product and the technicians should ensure that there is no damage during the
installation.
Grill doors are fixed with the use of 4 to 5 hinges, as per the load and design of the door.
After the hinges have been fixed in a proper position, the crane will be disengaged and removed from
the door.
Check that the allowed tolerances between the frame and the door are implemented.
Install the additional hardware e.g. dropping or industrial hinges, tower bolts, etc. are in accordance
with the manufacturer’s specifications.
Work Inspection Demand (WIR) must be made for each stage as per the Inspection and Test Plan (ITP).
The doors that are installed should be protected against material shifting and site activity.
9. Ironmongery Installation
In accordance with the approved shop drawings, the installer should fix the ironmongery proper way.
Adequate protection must be installed to prevent damages.
10.Vision Panel Installation (if there is one):
There are two components for the vision panel: both male and female pieces (vision light frame).
Before attaching both the male and female components, the glazing tape should be fixed to the
beading of the vision frame.
The male component is to be placed into the door cutout from the inside of the room.
Visibility glass must be fixed to the correct spot.
The female component must be accurately positioned and set. It is to be installed onto the male
component.
11.Louver Installation (if any)
Self-attaching (25mm) head screws can be used to attach the auxiliary frame onto the louver core
through the door’s cutout. The side that runs along the corridor part of the frame is completely free of
fasteners to provide additional security.
12.Final Alignment
After the installation, the proper door’s swinging and locking mechanism should be checked.
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13.Application of Fire Rated Sealant
Make sure that the surfaces are dry, clean, and free of frost. Clean the joints thoroughly to ensure that
the adhesion between the sealant and the surface isn’t compromised.
It could be necessary to mask areas adjacent to protect against contamination and to create a clean
sealant line. Masking tapes must be removed following the tooling and finishing.
Install the backing material as needed and complete the cavity with acrylic.
Joints must be tipped within 5 minutes after application to ensure that there is a good bond between
the acrylic and substrate. The process of tooling the sealant can also give an even and smooth
appearance.
Used cartridges shall be disposed of according to local rules.
14.Repair work (paint touch-up)
It is to be done in accordance with the specifications of the project.
Below are guidelines to be followed:
Sand the area that is damaged using sandpaper. This will remove any paint or rust from the affected
area. The damaged area should be sanded until the surface is smooth and soft and there is no visible
lip in between the steel and the paint.
Fill in the damaged area. Make use of a putty blade to fill the region with putty filler.
Smooth the putty out so that it blends in with the rest of the door.
The patch should be sanded: Once you have the patch looking nice and dried, make use of fine-grit
sandpaper to gently smooth the patch. Remove the fine dust using a cloth prior to applying the paint.
The patch should be painted with the identical approved color. If you are applying the paint to your
patch, apply either the brush-on method or a spray-on method.
Apply a thin coating of paint, let it dry completely, before applying a second thin coat. Continue to
apply thin coats until the spot disappears and the door appears to be completed.
Applying several light coatings of the spray paint will reduce the chance of messy paint drips and give a
nice, clean finish on the exterior that the door.
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METHOD STATEMENT FOR
EPOXY RESIN COATING WORKS FOR
FLOOR
SR. EFFECTIVE REV. MSS MANAGER MSS PROJECT CLIENT
CLIENT QA/QC
NO. DATE NO. QA/QC MANAGER SUPERVISOR
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EPOXY RESIN COATING WORKS FOR FLOOR
1. PURPOSE
The method statement for epoxy resin coating for the floor defines the sequence, quality control
procedures and safety guidelines for epoxy flooring works.
This work method statement covers activities related to epoxy floor coating works on various locations
as applicable and excluding traffic/vehicular areas.
2. Definitions
Developer/Client-xxxx
Supervising Consultant-xxxx
Main Contractor-xxxx
QC-Quality Control
HSE-Health Safety & Environment
PPE-Personal Protective Equipment
3. References
Project Specifications
Contract Specifications
Architectural Specifications
Epoxy Resin Floor Coating
Health and Safety Plan
Construction and Environmental Management Plan
3. Responsibilities
1. Project Manager
Responsible for accomplishing the stated objectives which include creating clear and attainable
objectives, building the requirements, and managing the cost, time, scope, and quality.
2. Site Engineer
Supervise operations in accordance with the approved method statement, shop drawings,
specifications, approved material submittal, and schedules to achieve the acceptance of the
deliverables.
3. Site Foreman
To liaise with the Site Engineer and Supervisor for the work execution.
4. HSE Manager
Health, safety, and environmental (HSE) managers generally plan, coordinate and implement issues
and directives within the organization.
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They ensure safe environmental working conditions for all employees.
5. HSE Supervisor/Officer
The Safety Engineer should be full-time at the site and should frequently visit all the ongoing activities.
All safety violations and on-conformance of the plan shall be registered and immediate action will be
done in coordination with the Site Engineer.
6. Scaffolding Manager/Supervisor
Ensuring safe access is provided for scaffolders’ jobs.
Ensuring that all his foremen, construction team leaders, construction staff, and workers are
conforming to work safety regulations and are Third Party Certified (TPC).
Ensuring that all scaffolds are erected according to scaffold methods.
Ensuring that scaffold schedules are met and still working within the safety requirement.
Ensuring that material and workers are available to meet the scaffolding requirements.
Ensuring that all documentation adheres to ToolBox Talks, Harness Inspection, Work Request System,
Scaffolding Tagging System, and Safety reports.
7. QA/QC Engineer should ensure are ongoing as per specifications and the document should follow as
per ITP.
8. Tradesmen (Workers)
The workers should aware of the nature of the job and should know the approved system, however,
the tasks and the quality must be ensured by the site engineer and QA/QC Engineer.
4. Resources
4.a Tools and Equipment
Approved scaffolding-For working at height
Confined space rescue-For emergency rescue
Multi-gas detector-For gas test inside confined space
Lighting facilities-For lighting of job area
First aid box-For emergency first aid
Exhaust fans-For ventilation
Barricading and fencing-For preventing unauthorized access
Protective clothing (gloves, overalls, goggles, and face masks)-For safe working
Slow speed drill, 400 or 500 rpm, plus mixing paddle and mixing vessel-For mixing
Grinder & vacuum cleaner-For surface preparation / floor preparation
Rollers, scrappers & brushes-For painting application
4.b Workforce
Site Engineer
QA/QC Engineer
HSE Officer
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Team Leader/Foreman
Technicians
Applicators
4.c Light Tools
Drill Machine
Slow speed drill machine
Surface Grinder
Hand Grinder
Vacuum Cleaner / Dust Collectors
Industrial vacuum machine
4.d Materials
Epoxy Paint Application–Sikafloor 264 – Approved material
Floor Putty–Sikafloor PS
Aggregates–Sikadur 507
5. Methodology-Epoxy Coating Works for Floor
General
This methodology specifies the requirement for 2 coats of epoxy flooring in concurrence with the
manufacturer recommendations, requirements, and other related detail specifications.
The working area will be barricaded and restricted from the entry of unauthorized personnel.
It will be properly illuminated and necessary warning signs to be installed in the proper location.
All scaffolding activities and ladders for access and egress will be erected by certified scaffolders. All
erected scaffolding access and egress will be inspected and tagged prior to use.
The relevant permits to be fully complied with by the working team prior to commencing activity and
ensure its validity.
Part mixing is acceptable as per requirements. However, once the pack is opened and not in use this
must be tightly sealed with the lid (material to be checked prior to the next usage).
All workers to be involved in the activity will receive proper information, instructions, training, and
adequate supervision during the activity. All workers will be briefed as well with the safe system of
task and procedure along with the use of proper PPE’s and emergency rules.
Relevant entities which might need protection include any type of work in the area vicinity of work,
service access, or discharge path.
6. Procedures-Surface Preparation
The existing area which requires refurbishment must be prepared to ensure a strong adhesive bond
between the first coat and the existing concrete area.
Clean the surface by grinding means of heavy-duty substrate grinders to remove the previous coating,
laitance, and other contamination such as oil, grease, mortar and paint splashes, etc. (Any sharp edges,
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protrusions, imperfections, or surface undulations in levels to be ground and made well by the client
free of charge.)
Vacuum clean to remove the dust and other loose particles.
Before application, all surfaces must be dry and free from oil, grease, decayed matter, moss or algae
growth, and general curing compounds. All such contamination and laitance should be removed by the
use of mechanical means.
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The surrounding surfaces which are not to be coated but which may be affected by the coat
application should be protected.
Fill all exposed blow holes, routed out cracks, etc. with SIKAFLOOR PS up to a rate of 0.1 to 0.2 kg/m²
to obtain a uniform surface of texture similar to medium sandpaper.
7. Substrate Pre-treatment
The concrete substrate must be sound and of sufficient compressive strength (minimum 25 N/mm 2)
with a minimum pull-off strength of 1.5 N/mm 2.
The substrate must be clean, dry, and free of all contaminants such as dirt, oil, grease, surface
treatments, etc.
Concrete substrates must be prepared mechanically using abrasive blast cleaning (blasting method) or
scarifying equipment
to remove cement laitance and achieve an open textured surface.
Weak concrete must be removed and surface defects such as blowholes and voids must be fully
exposed.
Repairs to the substrate, filling of blowholes/voids and surface leveling must be carried out using
appropriate products from the Sikafloor, Sikadur, and Sikagard range of products.
All dust, loose and friable material must be completely removed from all surfaces before application
of the product, preferably by brush or industrial vacuum.
8. Epoxy Paint (Sikafloor 264) Implementation
SIKAFLOOR 264 is a two-part High-build Solvent Free Epoxy Coating. Suitable for use in hot and
tropical climatic conditions.
Stir separately components A and B of SIKAFLOOR 264 well with an electric mixer, add the full contents
of component B into component A, and mix with a slow speed mixer (300–400 rpm) for at least 2
minutes until a homogeneous mixture is achieved.
Place mixed material into a clean container, mix again for one minute.
Prior to the application of epoxy – SIKAFLOOR 264, the surface should be thoroughly cleaned to
remove any traces of dust or other debris.
Apply the primer to the prepared surface prior to utilization of floor putty.
Afterward, apply the epoxy mixed material by roller using the consumption of 0.25 kg/m², taking care
to ensure good wetting of the substrate but avoiding puddles on the surface. Allow drying.
Followed by the second coat of SIKAFLOOR 264 using a roller or brush at a rate of 0.25 kg/m² ensuring
that the surface is fully covered and that no ponding of the material occurs. The coat should be applied
evenly over the floor surface to ensure a regular film thickness.
The minimum interval between the coats is as follows:
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Freshly applied SIKAFLOOR 264 should be protected from dampness, condensation, and water for at
least 24 hours. Due to the nature of the activity, for damages on the finished surface, rectification will
be done as per manufacturer recommendation which will depend on the type of damage.
Droppings and other foreign matters on different surfaces will be removed and cleaned immediately
after the completion of each application.
9. Thickness and Application Rate
Effective Covered Area
Sikafloor PS-0.200 kg/m²
Sikafloor 264 (1st coat)-0.250 kg/m²
Sikafloor 264 (2nd coat)–0.250 kg/m²
10.Types of Damages and Remedies
High spots to be removed by means of grinding by the use of the grinding machines.
All dust, loose and friable material must be completely removed from all surfaces before application of
the product, preferably by brush and/or industrial vacuum.
The substrate and uncured floor must be at least 3°C above the dew point to reduce the risk of
condensation or blooming on the floor finish.
Low temperatures and high humidity conditions increase the probability of blooming, thus weather
conditions should be monitored always prior to any kind of coating.
Over mixing must be avoided to minimize air entrainment, since pot life of any kind of epoxy to be
followed as per technical data sheet thus the area to be calculated prior to mix the material else it will
lead to overconsumption or wastage.
Damage area should be found and analyze the root cause for repair, then the area to be repaired
should be square cut and repeat the same application procedure, however, due to material property
the color difference may occur.
11.Risk Assessment-Method Statement for Epoxy
Please refer to the attached document in Appendix A.
12.Inspection and Test Plan
Refer to Appendix B for Inspection & Test Plan
13.Drawings
Not applicable since the coating applications will be followed as per specifications.
14.Pre-Start Safety Briefing Arrangements
Refer to Risk Assessment on Appendix A.
15.Protective and Safety Equipment
All workers involved will be equipped with adequate PPE as stated below:
a. Safety Helmet with company logo
b. Safety Boots
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c. High Visibility Vest
d. Safety Goggles
e. Hand Gloves
f. Coveralls
16. Information to Personnel
a. Safety Induction
b. Job Training
c. Superintendents Notices/Memos
d. Toolbox Talks
e. STARRT Card
17. Supervision and Monitoring Arrangements
Construction Manager
He is in charge of all construction activities. Schedule the site in logical steps and budget time required
to meet deadlines. Inspect and review works to monitor compliance with building and safety codes
and other regulations.
Site Engineer
The Site Engineer will evaluate the number of materials consumed by each trade to be compared
against the planned quantity.
Site Foreman
A site foreman is responsible for supervising the workers and also doing actual activity. The foreman
monitors employees to make sure that the work is done efficiently and within quality standards.
Chief Surveyor
A Chief Surveyor ensures that surveying data are collected and recorded accurately and that all
company guidelines are followed by crew members.
QA/QC Engineer
The QA/QC Engineer will monitor whether the installation activities are conforming to the required
quality otherwise he should notify the Site Engineer should he find non-conformance to the ongoing
construction activities.
The Site Engineer should immediately rectify the work to avoid receipt of non-conformance from the
quality engineer.
HSE Engineer
The Safety Engineer will be full-time at the site and will frequently visit all the ongoing tasks. All safety
violations and non-conformance of the HSE Plan will be registered and immediate action will be done
in coordination with the Site Engineer.
Scaffolding Manager/Supervisor
Ensuring that all his Foremen, Team Leaders, and workers are conforming to safety regulations and are
Third Party Certified (TPC).
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Ensuring that all scaffolds are erected according to scaffold methods.
Note: Site Engineers/HSE staff should have access on-site to civil method statements and risk
assessment
18. Environment and Quality Issues
Precautionary Measure
All precautionary measures will be briefed to all workers prior to commencing the activity.
Disposal Requirements
All waste will be disposed of as per the Construction and Environmental Management Plan, and as per
government-approved disposal areas.
Inspection, Test, and Sampling
Request for Inspection and Testing will be submitted prior to and after execution of works.
Quality Assurance Requirements Table
Ensure that work is executed as per approved shop drawing, method statement projects, and records
are generated referring to approved ITP.
Best management practices should also be considered which may be stated by product manufacturers
or suppliers.
Authority requirements will take precedence over all requirements in case authority approval is to be
secured.
For non-authority approval activities, the approved latest specification will take precedence.
It is to ensure that regular toolbox pieces of training-related work quality are conducted and records
are maintained
METHOD STATEMENT OF
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DRYWALL INSTALLATION FOR GYPSUM
BONDS
SR. EFFECTIVE REV. MSS MANAGER MSS PROJECT CLIENT
CLIENT QA/QC
NO. DATE NO. QA/QC MANAGER SUPERVISOR
DRYWALL INSTALLATION FOR GYPSUM BONDS
1. PURPOSE
The purpose of this method statement is to describe the installation stages required in installing
gypsum board for drywall and wall partition while assuring quality, and health & safety compliance.
This method statement is a written document that details how to properly and safely do a work-
related task using tools and equipment.
2. Work Description
The work involves the installation of exterior and interior wall partition and dry wall, as well as false
beams, columns, and other design elements, as described in the scope of activities. The walls will be
covered with the required and recommended dimensions, elevations, and levelness in accordance
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with the shop drawings.
The needed wall studs and blind rivets that will fasten to the concrete wall or bare wall are included in
the proper standard material required for the installation of the gypsum board wall.
The surveyor will mark the reference floor lines, ceilings, and wall locations for proper layout.
Install the gypsum board according to the arrangement with enough black screws to secure the boards
to the steel framing.
3. References
Project Specifications
ASTM C 36 Specification for Gypsum Wallboard
ASTM C 645 Standard Specification for Nonstructural Steel Framing Members
ASTM C 475 Specifications for Joints Treatment Materials for Gypsum Board
ASTM C 840 Specifications for Application and Finishing of Gypsum Board
ASTM C 754 Specification for Installation of Steel Framing Members
ASTM E 90 Standard Test Method for Laboratory Measurement of Airborne Sound Transmission Loss
of Building Partitions and Elements
4. Handling and Storage of Drywall Materials
Plasterboards and accessories should be brought to the job site soon prior to installation to minimize
the chance of damage.
Gypsum sheets should be handled and stored in an upright position, with special attention paid to
protecting the edges from harm.
The plasterboard should be stacked in a damp-free enclosed location in neat, balanced stacks off the
ground/floor. This will keep the board edges and surfaces from slipping and deteriorating.
If kept in an open area the gypsum sheets should be wrapped with plastic or tarpaulin to protect from
direct sunlight.
5. Installation Dry wall and Partitions Methodology
The building walls should be properly checked prior to the gypsum board installation to ensure that
the framing is plumb, level, and square and that the other trades have completed their ‘rough-ins.’
The stud and batten layout follow the lining spacing requirements listed in the frame spacing as shown
in the approved drawings. The plasterboard will be finished to the recommended level of finish once
the installation is complete.
Check that the steel framing has been constructed and erected as per the manufacturer’s
specifications and drawings before applying plasterboard to it. The steel frame’s contact surfaces are
clean, dry, and free of contamination such as oil, grease, and dirt.
Steel furring channels are attached to the underside of joists at right angles with clips or fasteners.
Anchor clips are used to secure steel furring to a concrete slab ceiling during false ceiling execution.
Furring channels should be spaced according to the thickness of the sheet specified in the Frame
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Spacing.
Plan the installation carefully. Sheets should be laid out in a way that ensures maximum coverage
while minimizing butt joints and waste. Plasterboard is typically installed horizontally in residential
construction and is critical if a Level of type finish of 3, 4, or 5 is desired (or as per project
specifications). If the sheeting is to cover the entire wall and wall partition, it can be fixed vertically.
6. Control Joints in Walls and Ceilings Provisions:
Should be spaced at a maximum of 12 meters in both directions
Every material change
In the structure substrate’s control joints
Every time the substrate material is changed
7. Plasterboard Adjustment System should be used based on the substrate:
Adhesive and fastener combination
Screw fixation
Nail fastener
To create precise sharp lines, avoid cracking, and provide a greater level of impact resistance, a
number of trimming options are available for plasterboard corners, edges, and joints.
Plasterboard trimming can be modified with nail, staples, or cornice adhesive, then terminated and
finished with the standard three-coat technique.
There are several types of shadow gap/shadow line effects that are needed, including:
Plasterboard and masonry wall junctions
Ceiling and wall junctions
Door and window jambs
8. Fixing of Metal Studs and Runners
Follow ASTM C 754 for installing studs and runners.
Metal stud spacing shall be 400mm from center to center as specified in the contract drawings.
Metal runner horizontal spacing shall be 1200mm from center to center.
Install metal runners at the bottom, both sides, and top of each wall to the slab/bottom beam’s level.
Fix metal studs and runners around openings, MEP services, and doors as per the manufacturer’s
recommendations.
Refer to the contract drawings for partitions that extend to the concrete slab’s beam and partitions
that reach through the ceiling to the structure above.
To avoid deflection transfer to studs, maintain clearance under structural building members.
Double studs at door frame jambs are required for door opening framing.
9. Installing Gypsum Board
Insert rock wool insulation between vertical studs and the slab/bottom beam’s level.
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Fixing gypsum board panels in the most cost-effective direction for framing furring members is
recommended.
Install single-layer fire-rated gypsum board as per the specifications of the U.L. fire resistance
requirements.
Apply sealant to cut edges and holes in fire-resistant gypsum board and outside soffit board.
When attaching gypsum board to metal or frame, use screws.
Apply gypsum board to curved walls according to the manufacturer’s instructions.
Except for fire-rated walls, which must be full height to the underside of the roof slab, all gypsum walls
must be extended up to the suspended ceiling or as shown in the drawing.
In wet areas, all gypsum walls must be moisture resistant. For all gypsum board wall corners, inside
mesh tape/corner tape must be provided.
10.Joint Treatment
Tape, fill, and sand exposed joints, edges, and corners to create a smooth, ready-to-finish surface.
Feather coats adjoining surfaces to achieve a maximum camber of 0.8mm.
Surfaces behind adhesive-applied ceramic tiles do not require taping, filling, or sanding.
11.Texture Finish with Enamel Paint
Finish texture coatings should be applied in accordance with the specified schedule for finishing paints.
12.Tolerance
The maximum deviation of the completed gypsum board surface from true flatness in any direction is
3mm in 3.0m.
13.Supervision-Installation of Drywall
Installation must be done by qualified and skilled installers with experience with board execution. They
are accompanied and assisted by unskilled helpers.
Supervisor, Site Engineers/Architects will be present to coordinate and communicate with other
stakeholders, such as subcontractors and the main contractor, and third parties to look into technical
issues.
Assign a competent site engineer to oversee this activity, ensuring that the Method Statement, ITP,
specifications, and other related documents are followed.
14. Tools and Equipment
Spirit level
Measuring tape
Water hose level
Right angle
Grinder with metal cutting blade
Plumb bob
Laser level
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Chalkline
Ladders
Screw Gun
Iron Scissor
Cutter
Paint brush
Drywall Materials
Gypsum Boards
Wall metal studs
Metal Runner
Connecting Clip
Rock wool insulation material-size of 50mm thick with density = 50 kg/m3
Black screw
Steel Framing
Blind Rivets
Shadow line
Corner Bead
Casing Bead
Gypsum Putty/Joint Compound
Wire mesh tape/Joint tape
Enamel Paint
15.Health, Safety and Environment Procedures
All Occupational Health, Safety, and Environmental regulations shall be rigorously followed.
By wearing proper and prescribed overalls, safety shoes, goggles, hand gloves, and helmets, the entire
workforce will comply with the organization’s hse compliance policy.
During the work process, enough lighting and ventilation will be provided.
It will be assured that all of the machinery and tools utilized are safe and in good working order at all
times.
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16.Method of Statement for Drywall-Quality Control and Assurance
Only calibrated tools will be used where applicable.
Setting plumb to highlight the specific places will be used to make markings on the wall.
Inspection Request will be submitted as per the Inspection and Test Plan of the project
General
Depending on the current site conditions, the right is reserved to change the technique from time to
time will be adopted.
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METHOD STATEMENT FOR
FIBER OPTIC INSTALLATION
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SR. EFFECTIVE REV. MSS MANAGER MSS PROJECT CLIENT
CLIENT QA/QC
NO. DATE NO. QA/QC MANAGER SUPERVISOR
FIBER OPTIC INSTALLATION
1. Purpose
The method statement for fiber optic cable defines the planning, site preparation, and installation of
exterior underground fiber optic cables, fitting accessories, and utility structures.
Installations will be located as shown on the approved construction drawings and as detailed in the
applicable specifications.
2. Scope
This method statement details the:
Methodology and sequence for the underground installation, termination, splicing, and testing of fiber
optic cable system under contract to allow the system to be fully functional and compliant with
standards, contract specifications, and approved drawings.
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Components of optical fiber cable
3. Risk Assessment
Hazard risk assessment and control measures for all activities involved in the underground fibre optic
cable system have been carried out in accordance with the project HSE plan.
4. Reference Documents
a. Approved Shop Drawings
b. Approved Materials
c. Project Specifications
5. Definitions/Abbreviations
a. IFC Issued for Construction
b. ITP Site Inspection and Test Plan
c. HSE Health, Safety, and Environment
d. PPE Personal Protective Equipment
e. PQP Project Quality Plan
f. NCR Non-Conformance Report
g. QA/QC Quality Assurance/Quality Control
h. SOR Site Observation Reports
i. MIR Material Inspection Request
j. WIR Work Inspection Request
k. MST Method Statement
l. OMM Operation & Manual (O&M)
m. CL Checklist
n. RA Risk Assessment
o. UPVC Un-plasticized polyvinyl chloride
p. PVC Polyvinyl chloride
6. Responsibilities
Project Manager
a. Project Manager (MEP) will be responsible for managing, execute complete and handover the
construction activities within approved budgets and resources in compliance with requirements as
specified in project specifications. He will be overall in charge of implementing the method statement
for fiber optic cable installation per QA/QC and HSE requirements.
b. Responsible for controlling the project’s entire activities & for the overall coordination with the
consultant/client.
c. Ensure that adequate welfare facilities and equipment are provided to the project to avoid injury,
health impairment, or damage & to ensure providing quality works within the planned time scale.
d. All responsibilities stated in the Project’s Quality Assurance Plan.
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Construction Manager
a. Organize the site so that work is carried out to the required specifications with minimum risk to
men, equipment, and materials.
b. Coordination with different functions with the project.
c. Expediting area of concern to achieve project schedule.
d. Adhere to the project-specific quality management program and HSE requirements.
QA/QC Manager
a. Responsible for the work of entire quality assurance, quality control & inspection programs.
b. Produce all quality-related documents & reports necessary as requested by the
Owner/Consultant/Engineer.
c. Provide written procedures & coordinate in formalizing the Method Statement for fiber optic cable
installation with the Project Manager/ Construction Managers/Site Engineers to describe the job-
specific work for each stage/activity.
d. All responsibilities stated in the Project’s Quality Assurance Plan.
QA/QC Engineer
a. Responsible for the work of entire quality assurance, quality control & inspection programs.
b. Produce all quality-related documents & necessary quality reports as requested.
c. Provide written procedures & coordinate in formalizing the Method Statement for fiber optic cable
installation with the Construction Manager/Site Engineers to describe the job-specific work for each
stage/activity.
Safety Manager
a. Manage Safety Engineers and Safety Officers to be in strict conformance with project policies and
procedures.
b. Must ensure safe work method as stated in MST and RA is fully implemented during activity.
c. Responsible for controlling HSE personnel for effective monitoring of work.
d. Oversee site safety orientations/inductions, toolbox talks, safety training certifications, job site
inspections, working at heights, scaffolding tagging systems are fully functional, rigging, etc.
e. Report to Project Manager all personal injuries and near-miss incidents (aligned with Safety
Engineers/Officers) as well as property damages immediately. Produce investigative reports and
summaries to senior management.
Safety Engineer
a. Ensure that all workers have a safe place of work, advise a safe system of work, and provide
adequate instructions, training, and supervision to enable employees to work safely.
b. Carry out site surveys on daily basis to ensure that the HSE methods of working are in operation &
that all regulations are being observed.
c. Report, determines & analyses the cause of any accident or dangerous occurrence and recommends
measures for preventing recurrence.
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Site Engineer
a. Adheres to the project-specific Method Statement for fiber optic cable installation, procedures,
inspection programs & HSE instructions to get the activities performed to client satisfaction with full
coordination with the HSE & quality personnel.
b. Responsible to ensure that correct drawings, materials, tools, and equipment are provided on-site.
c. Liaising with sub-contractors, supervisors, planners, quantity surveyors, and the general workforce
involved in the project.
d. Responsible for planning the work and efficiently organizing the plan and site facilities in order to
meet agreed deadlines.
e. Site engineer is responsible to coordinate with QA/QC team engineers/ inspectors, and handover
daily site progress works reports/highlighted drawings & present during inspection/site visit with
QA/QC inspectors & consultant/client.
Surveyor
a. Responsible for all survey works and report to Site Engineer.
Foreman
a. Performed the activities that were instructed by the Supervisor/Engineer at the site and follow the
safety procedures to make it safe for his workers.
b. In charge to lead the work execution send the focal point in coordinating with the site
Supervisor/Engineer related to overall site activity, materials, tools, and equipment.
Technician
a. Carry out Installation work as per the concerned foreman’s instructions with all the safety
requirements.
b. The workforce to attend daily toolbox talks, morning task briefs prior to starting any works EHS
(Environment Health Standard) plans and policies.
c. Carry out their work in such a way that they don’t create for themselves or any other person risk to
health safety, and don’t impact the environment to the maximum extent possible or affect the quality
of work.
7. Resources
This resource and manpower are not limited as above mentioned but will be increased and improved
as project requirement to implement the work without delay, with quality control and safety of
personnel.
7.1. Workforce
Manpower Required
a. Site Engineer
b. Supervisor
c. Foreman
d. Charge Hand/Supervisor
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e. HSE Engineer/officer
f. Surveyor
g. Plumber
h. Skilled labor as per the required work
7.2. Tools and Equipment
Operators of the equipment will be certified by 3rd party and have valid license/registration issued by
the traffic department.
a. Measurement tool
b. Pliers & equipment
c. Line marker
d. Hand cutter
e. Fiber optic disposal unit
f. Crimping tool
g. Fiber optic scribes
h. Fusion splicer & splicing hardware
i. Fiber optic strippers & sitters
j. Wrench
k. Miller riser cable tools
l. Pull rope
m. Digital cable meter
n. Jack stand/reel
o. Generator
p. Impact tool
q. Mid-span access tool
r. Stripper
s. Precision fiber cleavers
t. Temporary lighting
7.3. Materials
a. Fibre optic cable
b. Rack cabinet
c. Splice enclosure
d. Patch panel
e. Pigtail
f. Patchcord
g. Labeling material
h. Velcro tie/cable tie
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8. Sequence of the Works-Method Statement For Fiber Optic Cable Installation
a. The following methodology is for cable laying, testing & commissioning.
b. MEP will only commence after receiving clearance from other departments to start the underground
installation and cable laying.
8.1. Delivery of Materials, Storage, and Handling-Optical Fiber Cables and Accessories
1. Upon receiving cables, inspect protective cable covering for evidence of damage during shipment.
Report immediately to the carrier if evidence of damage is found.
2. Accomplish unloading without contacting cable surface or protective wrap. If unloading by crane,
use cradle supporting reel flanges or a shaft through arbor hole. If using a forklift, lift the reel at 90
degrees to flanges. Use forms long enough to make complete lifting contact with both reel flanges.
3. If using the inclined ramp for unloading, use a ramp wide enough to contact both reel flanges
completely. Accomplish stopping of reels at the bottom by using the reel flanges and not the surface of
the cable.
4. Do not drop reels from delivering the vehicle to the ground.
5. Store reels on a firm surface to prevent flanges from sinking into the earth and allow the weight of
the reel and cable to rest on the cable surface.
6. Do not store reels in an area where construction equipment, falling or flying objects or other
materials will contact the cable.
7. Store cable where chemicals or petroleum products will not be spilled or sprayed on the cable.
8. Store cable away from open fires or sources of high heat.
9. When a reel of cable is rolled from one point to another, check for and remove objects on the
surface that could contact or damage the cable surface or protective wrap. Roll reel in the direction to
prevent loosening of the cable on the reel.
10. Store cable according to manufacturer’s recommendations, as a minimum. In addition, store cable
in a location protected from vandalism and weather. If the cable is stored outside, it must be covered
with opaque plastic or canvas with provisions for ventilation to prevent condensation and for
protection from the weather. If air temperature at the cable storage.
11. Deliveries will be Inspected and handled at the site area according to the given instructed
requirements.
12. All uPVC, fitting accessories, utility structures, and fibre optic cable drums will be covered and
stored above grade in a secure and protected location in order to be protected from climate, dust, and
entrance of debris and will be codified for easy traceability.
13. Ensure that the proposed storage area for the materials is cleaned.
14. Separate areas in the storage zone must be marked for different materials.
15. Ensure that the material is stored in a shaded area to protect it from exposure to direct sunlight.
16. Ensure that the lifting equipment is adequately rated for the specked weight (shown on the rating
plate) and fit for purpose.
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17. Verify that the bracing & supports are provided to prevent damage during transit, lifting, or
unloading.
18. All materials received at the site will be inspected with the corresponding inspection request (MIR)
issued.
19. Ensure that the materials are as per the approved submittal any discrepancies Damages etc. will be
reported for further action.
20. Material found not suitable for the project will be removed from the site immediately.
21. When handling drums, suitable precautions should be taken to avoid damage to the cable and
injury to the people. Due regard should be paid to the mass of the drum, the method and direction of
rolling, and the method of lifting.
22. It is preferable for ease of handling and safety to move drums by special cable drum trailers and
whenever possible the cable should be laid direct from these. In certain cases, it may be possible to lay
a cable from a drum trailer whilst it is being towed alongside the trench, thus giving a considerable
saving in time and effort.
23. The drum mounting position, if stationary, will be influenced by the following:
Accessibility-Good access to where the cable drum is to be mounted.
Gradient-On sloping ground, cables should be pulled downhill.
Bends-The drum should be mounted at the end of the trench nearest the bends. The force required to
pull the cable is near to the drum, and therefore, the side forces and friction on the bends will also be
less.
24. Ducts-To minimize the disturbance to ducts and the resulting possibility of damage to the cables,
the drum should be at the end of the trench farthest from the ducts.
25. When rolling drums, it should be over short distances only and the drum rotation should always be
according to the arrow marked on the drum flange. This will ensure that any slack cable is worked to
the outer end. Failure to take this precaution may result in slack cable collecting at the hub of the
drum causing damage.
26. Cable drums should be transported with the drum axis horizontal and any drum movement should
be avoided.
27. Cable ends should be firmly attached to the drum during transport and storage to prevent damage
to the cable.
28. For loading and unloading of cable drums, suitable lifting and hoisting equipment should be used. A
drum should not be dropped.
29. Cable drum jacks should be mounted on a firm level base. If the ground is uneven, a foundation
should be provided by using stout timber solidly packed.
30. Timber packing may also be necessary to prevent settling of the jacks by spreading the weight if
the ground is soft. It may be necessary to locate the drum in the roadway away from the trench and in
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this case, the drum should then be offset by not more than 30 degrees to the line of the trench. For
safety, the drum should not be mounted closer than 1m to trench excavations of normal depth.
8.2. Site Execution
As follows are the procedures for the installation of optical fiber cable:
8.2.1. Survey Works
Surveyor will set out the location as per the approved shop drawing and MEP coordination with all
project services and it will be checked by QA/QC Engineer and after written approval, the installation
process will be started. A further survey will be carried out after the execution of the works for the
purpose of as-built drawings.
8.2.2. Work Permits
Before commencement of work, a “Permit To Work” indicating the activities to be performed will be
obtained from concerned authorities as per HSE policy and procedures.
a. The HSE department is authorized to issue and control work permits.
b. Make sure that every worker to perform the work has attended the specific safety training before
commencing work.
c. Work in a confined space require a work permit from the site engineer/site supervisor.
d. A permit will be required for hot work.
e. The result of the inspection with the permit to work will be communicated to all persons who will be
involved in the execution of the work.
8.2.3. Electricity
a. Before using an electric tool, check the tool and its plug and connecting cable.
b. Do not use damaged tools.
c. Do not use an electric tool unless its connecting cable is well protected.
8.2.4. Fire Risk
There is always a fire risk however the chances of fire can be reduced and you will know what to do
when a fire breaks out if you:
a. Always keep the workplace clean and tidy.
b. Handle machinery and tools that may generate sparks or hear carefully.
c. Know where fire extinguishers are located and how to use them.
d. Know the place of assembly for fire evacuation.
8.2.5. Load Shifting Machinery
a. Unless you are a worker concerned, do not work in an area where a lifter, crane (mobile/tower), etc.
is in operation.
b. Do not operate any load-shifting machinery without training and approval.
c. Operators of forklift trucks, bulldozers, loaders, excavators, trucks should possess appropriate
certificates/passes.
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8.2.6. Portable Power Tool
Do not use a portable power tool (such as a saw grinder and drill) unless its dangerous parts have been
effectively guarded.
9. Methodology
The procedures for the Installation of Underground Fiber Optic Cable are detailed below:
9.1. Pre-requisites
a. Check and the actual condition for installation of underground fiber optic cable.
b. Cable the approved issued shop/ design drawings.
c. Provide all necessary work permits; indicate all the activities prior to work execution.
d. Ensure the permit has HSE approval.
e. Provide sufficient safety signage and barricade the work area if needed.
9.2. Site Access
a. Clearly designated walkways must be established to allow persons to access the site safely.
b. Walkways must be maintained free from obstruction and any debris.
c. Adequate illumination must be provided for access routes and walkways.
d. Signs must be displayed to indicate the routes to be taken by persons, changes in routes must be
clearly communicated.
e. All safety measures will be taken care of as per the instruction of the HSE department.
9.3 Pre-installation
Before the commencement of installation, the following are required to be carried out:
a. Drawing for External Underground Fiber Optic Cable will be approved and will be coordinated with
other services.
b. Proper access will be provided as per the approved program.
c. Location/area will be ready for site installation.
d. Prior to the installation, the area where the items to be installed will be inspected.
e. Prior to the installation, check all cabling as per detailed drawings.
f. Mark the device/panels location and leave enough length of cable at both ends for termination.
g. An up-to-date test report will be checked.
h. All inspections (previously conducted) are checked and should be approved by the consultant
representative.
9.4. Trench Installation
If dewatering is required for trench preparation, this will be performed:
a. Trench sizes will be made as per the approved IFC drawings and as per the suitable trench size.
b. Inspection by the consultant representative has to be done for each stage.
c. Place approved bedding material to the extent necessary for establishing the correct elevation at all
locations where the bottom has been excavated below indicated grade.
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d. Good coordination with the civil team has to be done.
e. The bottom of the cable trench will be covered, to a depth not less than the diameter of the largest
cable, with a bedding layer of sand or fine soil.
The following criteria are to be followed as per project specifications:
Depth of the cable trench will be 950mm for MV cables.
Depth of the cable trench will be minimum of 650mm and maximum of 850mm for LV cables.
Cable trench will be bedded with 150mm thickness of dune sand.
Minimum clearance of 300mm from other services.
Dune sand will not contain stones, shrapnel and flints also free from other foreign materials.
f. Prior to installation of sleeve pipes, the trench preparation will be checked for the required
elevation, slope, and free from rock, stones, and other deleterious materials. The installation will be
not be started until unsatisfactory conditions have been corrected.
9.5. Procedure of Conduit/Sleeve Installation
UPVC/PVC Sleeve Installation (EN6) for Road Crossing of Fiber Optic Cables
a. Sleeves will be not be filled with cables to more than 60% of their capacity. Nylon drawcords will be
always be left in sleeves.
b. Before laying of sleeves. The trench bottom is of a smooth and firm contour and free from any sharp
materials or obstructions.
c. The trench should be sand bedded for 150mm. Then sleeve separators are used for underground
ducts installation and will be snaked to avoid tension during backfilling operations and subsequent
settlement.
d. Make joints in ducts and fittings watertight according to manufacturer written instruction. Stagger
the joints of multiple layers of conduits to not create a weak point in the duct run. Bell mouths are
installed at each end of the duct pipe.
e. Install no more than equivalent of two 90-degree bends between pull points.
f. No protective cap, disc, or other appliance on the end of pipe or fitting will be removed permanently
until the pipe or fitting which it protects is about to be jointed. Pipes and things will be examined for
damage and the joint surfaces and components will be cleaned.
g. Suitable measures will be taken to prevent soil or other material from entering pipes and to anchor
each pipe to prevent flotation or other movements before the works are complete. Before making the
joint ensure that both the pipe end and the sealing ring are clean. Lubricate both the pipe ends and the
sealing ring in the socket with lubricant.
h. Ensure that components to be joined (by push-t method) are correctly aligned, and then push the
spigot fully into the socket.
9.5.1. Installation of Optical Fiber Cables
a. Pre-installation inspection of optical fiber cable will be carried out as per requirement and recorded.
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b. All the cable rollers will be of sufficient size to accommodate the cable without any damage to its
outer sheath.
c. The cables will be laid in a sequenced manner.
d. The cable will be left from the bottom of the drum while pulling.
e. The pulling tension does not exceed the safe pulling tension of allowable force of the cable.
f. Check that the wire pulling sock will be tied to the cable end and the winch rope will be attached to
the sockeye if required.
g. Lubricate the cable, if necessary, from the drum end prior to its entry into the trench with the
approved pulling compound.
h. After cable pulling is completed and testing has been done, inspection to proceed for cable laying,
cable tiles, and backfilling.
i. As per the approved shop drawing, warning tape will be provided 300mm below the ground level
along the cable route.
j. Identify the cable route by placing the cable route marker at 30 meters of the interval to the straight
run and at points where the route changes direction to the entire route for cables.
k. Proper care will be taken while pulling the cables through sleeves to avoid damages.
l. Connect the strength member of the cable to the pull line. Unless cables are designed for such use,
basket grips and similar methods of attachment should not be used.
m. UL approved lubricant will be used to assist in pulling bar optic cable (if required).
n. Use a swivel while pulling to prevent the cable from being twisted by rigid attachment to a fish tape.
To keep pulling tension within careful limits, do not use power pullers with fiber unless you use a
tension meter as well. As a general rule, the tension should not exceed 300 pounds with indoor cables
and 600 pounds with outdoor cables. But always check the specifications for the cable to be sure.
o. Use lots of large pull boxes and divide pulls in half or even thirds at corners or pull boxes.
p. A pulling operation must be stopped if pulling tensions reach the cable’s limit.
q. The discontinued pull will have to be aborted, the cable pulled back out and replaced on the reel,
and the pull started again using shorter runs, better lubrication, or both the cable may be reused if the
pull or extraction has not damaged it.
r. Identify exact terminating locations in advance, keeping in mind that the cable must be pulled all the
way to where it will be terminated, not just into the room. This obvious though often overlooked step
can lead to costly mistakes if forgotten.
s. Carefully measure the cable’s path before the conduit pulls to avoid the need for splices.
t. Not only do splices cost time and money, but they also cause a loss in both signal qualities and
strength. In fact, most designers specify point-to-point or device-to-device runs to avoid needless
signal loss from splices.
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u. The preferred way to measure is to use a pull tape. This product, sometimes called mule tape, is an
at the ribbon, consecutively numbered in feet, which is usually made of polyester or aramid yarn and
may be coated with plastic for water prong. It comes in different lengths and pulls strengths.
v. Pull the pull tape into the conduit, or along the cable path, for an initial measurement, and add to
that extra length for splices, terminations, and future access coils, if specified.
w. The amount of additional optical fiber cable needed for splicing depends on site conditions, splicing
method used, and long-range plans for cable usage.
For termination length, about 2 to 3 meters of additional cable beyond where the terminal will be
mounted.
Add about 10 to 12 meters per span for any access or repair coils. A good rule of thumb to cover all
these additional cable lengths are to allow 1 percent extra for outside plant (outdoor) cable runs and 5
to 7 percent extra for inside cable runs.
x. Choose crews based on the length of the pull, total degrees of bend, tail loading (force required to
pull cable o feed reel), use of lubricant, and use of power putting equipment. In most cases, two- or
three-person crews are ideal. That way, one person pays the cable off the reel and into the duct, while
one or two others pull at the other end.
y. Don’t forget to mark the cable with marker tape buried below the surface; this will act as a warning
to anyone digging in the area. If you’re using a cable construction not containing metal, use a metal
impregnated marking tape so the cable can be located with appropriate equipment.
z. Aside from the regular work hazards of cuts, bruises, falls, etc., you must consider additional
hazards. Check for hazardous gases before anyone enters a manhole. In fact, you might need a
separate air supply. You’ll have considerable forces on the puller, sheaves, and/or pulleys. And, you
may be using pulleys 5 ft. in dia. If one of these is let go, serious injury can result. Your best bet is to
use chain or steel cable (chokers) rather than rope to tie pulleys and pull equipment in place. Above all
else: Examine each situation carefully before you start work.
aa. Guard the manhole a combination guard and emergency man lift is ideal. If the manhole is in a
high-traffic area, you’ll need a warning light. If the cable installation takes more than one day and you
leave it idle overnight, protect it during that time.
9.5.2 Identification of Electrical Services
Temporary identification labels and notices will be provided immediately after the installation
inspection is approved.
Warning, caution, and instruction notices will be provided temporarily. It will be ensured that all
identification labels and notices are installed in a visible position.
9.5.3 Redline Mark-up & As-built Drawings
If any changes occur in the routes (Non-adherence to the approved Shop drawings) then such
information will be detailed in the As-Built Drawings with Redlines.
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10. Testing of Installed Fiber Optic Cable System
a. Prior to testing the cable, the concerned Foreman or Engineer should make sure all the safety
precautions are taken and experienced technicians need to carry out the testing.
b. Testing will be done as recommended by the manufacturer.
c. After the installation of underground cable, insulation resistance test and continuity test of cable
need to carry out as per the Project specifications.
d. The QA/QC Engineer/Inspector will be responsible for completing Inspection Reports for these
activities.
e. Make sure the cabinet and surrounding area are dust-free.
f. Remove the dust cap and clean the inner part of the coupler.
g. Connect the test jumpers on both near and far ends (Power meter & light source)
h. Press the start button and begin the test.
i. Note down the test values on a chart for calculating average loss.
j. The same procedure will be repeated for all the cores.
11. Quality Control-Method Statement For Fiber Optic Cabling
The Inspection and Test Plan (ITP) for this Method Statement For Fiber Optic Cable Installation
summarizes various characteristics to be checked.
The concerned Site Engineer or Site Supervisor will be responsible for ensuring compliance with these
operations. The site QA/QC Engineer will carry out quality control checks and report the inspection
results.
11.1. Quality Records
a. Quality records will be provided as identified in the ITP and maintained as per ISO 9001.
b. Required forms of records and reports are defined in the Inspection and Test Plans.
c. Required tests will be carried out as mentioned in ITP.
d. Submission of as-built records will be done after completion.
11.2. Specific Quality Measurements
a. All works will be undertaken in compliance with the quality requirements of the contract.
b. Where non-conformance is found/identified to demonstrate its conformity. All works requiring
inspection and testing to demonstrate conformity with requirements will be undertaken in accordance
with the “Control of Inspection and Testing”.
c. Where non-conformities are found/identified, they will be addressed in accordance with “Procedure
for Control of Non-Conformances”.
The quality control activities associated with the works will be conveyed to all personnel involved in
the execution of the works by the Project QA/QC Manager prior to the commencement of the work.
The equipment and instruments used for measurements on-site will be calibrated and certified.
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The relevant documents will accompany the corresponding equipment and instruments. Necessary
internal and external training is provided to the staff carrying out the job to ensure that the quality
standards required on the project are met. Skilled and competent personnel are deployed to
undertake the job.
12. Health and Safety
12.1. Specific Health & Safety Requirements & Precaution Measures
a. The works will be carried out in compliance with the applicable HSE legal and contractual
requirements as well as Health and Safety Plan.
b. Any emergency situations that may occur on-site will be dealt with following the procedures,
responses, and controls as described in the Emergency Preparedness and Response Plan.
c. The significant HSE hazards and risks related to the works covered by this document have been
identified, and documented in “Risk Assessment”.
d. The environmental hazards and risks will be identified and documented in accordance with the
Environmental Risk Assessment Plan.
e. The identified hazards and associated risks and mitigation controls will be communicated to the
workforce through registered pre-task briefings at the beginning of each shift.
f. Daily task briefing will be performed prior to commencement of works.
12.2. Personal Protective Equipment
The minimum PPE as per the project HSE plan that all personnel involved in the works will wear:
Safety Helmet
Safety Shoes
High Visibility Vest
Protective eyewear (glasses)
Gloves
Personnel not directly involved in physical work, who are visiting the site must also wear all the
required personal protective equipment at any time they are outside of their vehicle, except gloves,
which are discretionary.
Personnel who are visiting the site but not leaving the PPE “free” designated areas which, if present on
the site, will be clearly defined by signs and barriers (typically around the offices and car park), are not
required to wear PPE (but it is recommended, especially protective eyewear).
12.3. Manpower
a. Safety and health induction will be conducted by Health & Safety department before the
commencement of works to each person involved in works. All operators involved in the execution of
the work and the workers who undertook critical tasks will be competent and certified to undertake
the works. The drivers will hold a valid license.
b. All workers will receive a daily briefing about the works they have undertaken that day.
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c. All personnel will wear the required Personal Protective Equipment (PPE) in accordance with the
Health and Safety Plan.
d. The Site Engineer is responsible for the job and will be present at the site during working hours and
a Safety Officer as well to monitor all activities.
e. Any incident, injury, and near-miss will be reported immediately to the Safety Department and Site
Manager.
f. The welfare facilities (see Health and Safety Plan) for the site work including drinking water cooler,
shaded area, worker’s toilet blocks, dedicated smoking area, emergency standby vehicle will be
established prior to commencing the works.
13. Appendices References
Appendix A – Inspection and Test Plan
Appendix B – Inspection Check List
Appendix C – Risk Assessment
Appendix D – Reference Drawings
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METHOD STATEMENT FOR
WATER HEATER INSTALLATION
SR. EFFECTIVE REV. MSS MANAGER MSS PROJECT CLIENT
CLIENT QA/QC
NO. DATE NO. QA/QC MANAGER SUPERVISOR
WATER HEATER INSTALLATION
1. PURPOSE
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The Method Statement for Water Heater Installation describes how the supply and installation of
water heaters and related accessories should be done in a safe way as per HSE and project
requirements.
Likewise, all quality assurance and control activities are conducted in a systematic way, where works
are inspected to ensure that they are compliant with project specifications, which are verified and
documented by ensuring the approval of the client’s representative.
2. References of Method Statement for Water Heater Installation
This method statement is subject to the requirements as stated in the following regulatory & statutory
documents, applicable standards, specifications, and building codes:
Project Specifications
Project approved IFC drawings & Materials
Approved Project HSE Plan
Approved Project Emergency Response Plan
Approved Project Waste Management Plan
3. Access
Works will be started or carried out only when all associated main contractors procedures are
completed and by ensuring safe access to work areas will be available through hoist lifts/access
ladders to carry out the work whenever main contractor site engineer’s & safety officers clearance is
available.
4. Logistics
MEP subcontractor will deploy a dedicated team for the required logistics and material movement in
and out of the project.
5. Health, Safety & Environment Hazards
Extreme heat and humidity
Extreme cold, high winds and dusty condition
Mobile equipment-crane, forklift etc. for material loading/offloading, transfer of materials to work
locations
Temporary electrical supply for lighting, use of power tools etc.
Improper stacking of materials
Manual handling/offloading & installation of water heaters
Working on unsafe scaffold for the installation of water heaters.
Damaged hand tools-installation of water heaters
Uninspected power tools – drilling of holes for anchors
Unsafe working on ladders
Poor housekeeping & waste management
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MEP subcontractor will comply with all safety measures as applicable to project main safety
requirements and follow approved HSE plans.
Information to personnel regarding Health and Safety:
o Site Safety Inductions
o Ensure STARTT is discussed with the work group prior to works commencing
o Safety toolbox talks
o Environmental toolbox talks
o HSE training records / Toolbox attendance register
o Training courses ( Internal and Third party Training)
o HSE Bulletin/HSE Site Notice Boards
o Site Engineers, Site Supervisors and Site Foreman
Permits and Certificates:
o HSE Permits and Certifications (as per activity requirements)–These should correlate with the activity
Risk Assessment.
Permit To Work (Prior to start an activity):
o Ensure obtain necessary PTW (Permit to Work), prior to allow to work. Frequently trainings should be
conducted by site supervisor/foreman. Daily safety briefing should be conducted.Hot work permit
o Lifting Plan
o Working at heights/working on scaffolding or MEWP (Mobile Elevating Work Platform)–Third party
certification for workers (competency certificates), operators and the equipment.
6. Definitions
MST–Method Statement
QCP – Quality Control Procedures
ITP – Inspection and Test Plan
PTW – Permit to Work
HSE – Health, Safety & Environment
EWH – Electric Water Heater
Responsibilities/Supervision
Project Manager
The project manager shall manage overall project planning, procurement, technical submissions, and
drawing submissions.
The project manager shall coordinate activities within the site team and with the management for the
prompt completion of activity by contract requirements.
Construction Manager
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The Construction Manager manages the work execution in compliance with the approved Method
Statement for Water Heater Installation, HSE Risk Assessment, project specification, issued for
construction drawings, sections, and details.
Project Engineer
The Project Engineer for each discipline shall manage the execution of the complete system by project
requirements. He will manage the day-to-day activities on-site, for materials, drawings, testing &
commissioning, and allocation of departmental resources to work areas on site.
The project engineer will report to MEP Project Manager.
The Project Engineer shall coordinate all related MEP system activities with all other trades for
progress monitoring.
Site Engineer
The Site Engineer is responsible to carry out the work as per approved shop drawings and method
statements. He is also responsible to ensure adequate tool kits required for the works are in place
prior to the starting of work. The Site Engineer reports to the Construction Manager.
The Site Engineer is responsible to ensure work has been done as per the specification and drawings;
inspections are carried out based on ITP and quality control procedure and coordinate with QA/QC
department for consultant inspections.
The Site Engineer is responsible to ensure that all safety precautions are ensured in place and that all
personal on-site are using the required personal protective equipment like helmets, gloves, shoes, and
reflective jackets. The site engineer in coordination with safety officers will ensure all relevant
permissions are taken prior to commencement of works.
QA/QC Engineer
QA /QC Engineer will be responsible for overseeing the quality requirements and quality control
measures for the project in coordination with the Project Engineer and Construction Manager.
Safety Engineer
The Safety Engineer will be responsible for the safety, health, and environmental aspects on site as per
the project safety and environmental requirements/safety standards in coordination with the project
engineer and construction manager.
7. Method to be Employed
6.1 Material Handling & Storage
On receipt of pipes and fittings, the materials shall be handled and stored in line with the following
procedure:
All materials delivered to the site shall be new, free from defects, and of the same type & model as per
approved material submittal.
The materials should be received factory packed and should remain so until installation.
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Delivered materials shall be carefully off-loaded using necessary manpower, or lifting equipment as
necessary to ensure no damage occurs. All lifting & handling procedures will conform to the
manufacturer’s recommendations.
Upon completion of receiving inspection, the Electric Water Heater units will be segregated
model/size-wise and stored accordingly for easy identification.
Materials to be stored on a flat surface in well ventilated, dry, and covered storage area.
Electric water heaters and their accessories shall be transported to the site in their original packaging.
Sufficient manpower & appropriate lifting equipment shall be used to load and transport the materials
to the site/installation area.
Electric water heaters shall be fully protected/covered at all times.
6.2 Preparations/Pre-installation checks
Ensure that the Method Statement for Water Heater Installation is approved and the material
delivered is inspected & approved by the consultant representative.
Confirm all approvals such as layout/detailed shop drawings, MEP coordination drawings, material
submittals are available.
Ensure the materials/accessories that are available which are received from the store are free from
damages during transportation.
Check & coordinate with other trades/services prior to the installation. Ensure all civil works are
completed for the area of installation plastering, painting, etc.
Ensure that the exact location of EWH is coordinated with the electrical layout to have access to the
power supply layout.
Verify the ceiling space clearances in coordination with the approved ceiling layout plans.
Ensure there is adequate space around water heaters for removal and maintenance.
Obtain work permit prior to commencement of works.
8. Installation-Method Statement for Water Heater
7.1 Installation of Electric Water Heaters
Follow the manufacturer’s procedure on how to install the electric water heaters.
Select the installation as per the approved shop drawing and coordination drawing.
Confirm the correct model no., size & capacity of the electric water heaters & mark the final location
for installation.
Make sure EWH is mounted on the wall surface. Mark and drill correct holes for the bolts.
If it is not possible to directly install the EWH on the wall surface, use additional steel supports as
required such as C- channels, angle bars, etc. Mark and drill correct holes for the bolts of the frame on
the walls.
Use appropriate drilling machine to drill for required diameter/size of screws insertion on the wall with
a correct drill bit and ensure that all fasteners are properly tightened, supports are aligned & secured.
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Raise and install the EWH gently into the wall bracket/structure supports.
Ensure the EWH is properly installed, all screws are fastened and supports are rigid.
7.2 Piping Connections to Electric Water Heaters
Install the cold water supply inlet & hot water supply outlet piping by removing the temporary caps
from the inlet & outlet connection nipples. Re-check to ensure that all pipes, valves, fittings &
accessories are properly connected and the direction of water flow is correct.
Install valves and other accessories as per the latest shop drawing. All valves to be installed should be
located for easy access to closing maintenance purposes.
Install the temperature & pressure relief-safety device valve as per the manufacturer’s
recommendation.
Provide proper pipe supports and pipe hangers to the associated piping, ensure pipe supports, and
hangers are secured.
Provide proper identifications, tagging & labeling of pipes for flow direction of the water.
Provide access doors for EWH where ever necessary/applicable for maintenance purposes.
A thermostatic mixing valve will be installed for the regulation of the hot water supply to the building.
Approved standard detail will be followed for the installation of the thermostatic mixing valve.
9. Labeling & Identification
Locate pipe labels/water heater labels where piping is exposed or above accessible ceilings in finished
spaces; machine rooms; accessible maintenance spaces such as shafts and exterior exposed locations
as follows:
At access doors, manholes, and similar access points that permit view of concealed piping.
Near major equipment items and other points of origination and termination.
On piping above, removable acoustical ceilings.
Where the change of direction occurs in piping.
Omit intermediately spaced labels.
The color coding and type of labeling/identification shall be as per approved material submittal &
relevant project specifications.
10.Training
All required training for stipulated installation activities is provided to all contractor’s technical staff for
ensuring quality workmanship.
11.Resources
10.1 Manpower
Subject to main contractors programmer and scope/area available for MEP activities, but not limited
to below:
MEP Supervisor
Foreman
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TITLE:
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Charge hands
Plumbers, pipefitters
Assistant fitters
Helpers
10.2 Material
Ensure material being used are of approved manufacturer from project vendor list and of quality as
specified – Electric Water Heater with accessories.
10.3 Tools & Equipment
Approved threaded rods & hanger supports
Hacksaw and blades-Chalk line/chalk powder
Portable hand tools-grinder/hammer-drill
Brush and clean waste/cloth
Spirit level & water level pipe
Standard toolbox set
Flood lights (For night works)
Measurement tape
12.QA/QC Requirements
Follow approved Method Statement for Water Heater Installation, ITP, QCP, HSE Plan, and Material
Approval & Checklist.
13.Supporting Documents
This Method Statement for Water Heater Installation is to be read in conjunction with the below-
referenced documents:
Project Specification & Approved drawings
Approved Value Engineering
Project Quality Plan
Project HSE Plan
14.Distribution
Copies of this Method Statement for Water Heater Installation will be circulated to the following for
information & action:
Construction Manager
Site Engineer
QA/QC Engineer
HSE Engineer
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15.Attachments
Risk Assessment
Inspection & Test Plan
Quality Control Checklists
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METHOD STATEMENT FOR
COPPER WATER PIPING HOT & COLD
INSTALLATION
SR. EFFECTIVE REV. MSS MANAGER MSS PROJECT CLIENT
CLIENT QA/QC
NO. DATE NO. QA/QC MANAGER SUPERVISOR
COPPER WATER PIPING HOT & COLD INSTALLATION
1. PURPOSE
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This method statement for water piping copper (hot and cold) installation is to ensure that all the area
and other related activity is executed safely and in accordance with the project specifications. This MST
establishes all quality assurance/quality control activity is conducted in a systematic manner, work is
inspected and conformance is verified and documented for the project as specified in specifications
and instructions.
2. Scope
This method statement for water piping installation is applicable to ensure that all hot and cold water
piping copper installations with complete accessories and workmanship are correct, acceptable,
functional, and conforms to the project specification and manufacturer’s recommendation.
3. References
Project Specifications
Approved Shop Drawings/IFC Drawings
Approved Material Submittal
4. Abbreviations
QC Quality Control
QA Quality Assurance
HSE Health, Safety and Environment
MEP Mechanical, Electrical & Plumbing
ITP Inspection & Test Plan
MST Method Statement
PPE Personal Protective Equipment
MSDS – Material safety data sheets
RSK Risk Assessment
PQP Project Quality Plan
QCP Quality Control Procedure
INR Inspection Request
5. Responsibilities
General
1. The Project Manager (MEP) will be responsible to manage, execute, complete and handover the
construction activities within approved budgets and resources in compliance with Project
Requirements as specified in Project Specifications. He will be overall in charge of implementing the
Method Statement in accordance with QA/QC and HSE requirements.
2. The Construction Manager will be responsible for managing construction activities and will lead and
communicate with site Supervision, Subcontractors, and vendors to assist them in working on the
project schedule by conforming to QA/QC and HSE requirements at the site.
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3. HSE Manager will be responsible for plan, coordinate, and implement issues and directives within the
organization. He ensures safe environmental working conditions for all employees.
4. QA/QC Manager will be responsible for supporting the project team in implementing and maintaining
Quality Management System for the project through PQP, ITP, MST, and Procedures in compliance
with project specifications, codes, and standards.
5. HSE Officer will ensure enforcement of safety procedures in accordance with the approved HSE Plan.
Will be closely monitoring the site engineer’s strict implementation of the MS and Risk Assessment,
the use of proper tools and equipment to maintain safety certifications of equipment and their
adherence to safety regulations, reporting of any unsafe work or stopping work that does not comply
with HSE procedures.
6. The Site Engineer will be responsible for carrying out all construction-related activities with compliance
to HSE and QA/QC requirements as per contract specifications, drawings/documents, codes, and
standards.
7. QA/QC Engineer will be responsible for conducting inspections as per PQP.
8. The supervisor/foreman will be responsible for coordinating all works and workers related to the job.
9. Electrician/other tradesmen will be responsible for assisting his superiors during all construction work-
related activities following HSE and QA/QC requirements.
10. Store in-charge receives and inspects all incoming materials and reconciles with documents; processes
and distributes documentation; reports, documents, and tracks damages and discrepancies.
6. Handling, Storage and Transportation
1. All materials shall be handled/transported/stored in an optimal way that will not cause damage to
them. Pipe shipping, storage, and handling shall comply with the
manufacturer’s recommendations. The material will be delivered at the site in undamaged condition,
in the manufacturer’s packaging, with identifying labels intact and legible.
2. Each shipment must be blocked and securely fastened to avoid damages during transportation.
3. Unloading at the site must be controlled by site management following the manufacturer’s
instructions.
4. Rubber gaskets should be kept clean and away from oil, grease, excessive heat, and the direct rays of
the sun.
5. Pipes are to be checked on unloading. Damaged and defective pipes shall not be used at the site. The
pipe shall be re-inspected just prior to installation. Possible damages are reported on the delivery
note.
6. Pipes or fittings will not be drop or drag.
7. Ensure that the material is stored in the shaded area to protect it from exposure to direct sunlight.
8. Leave sufficient space between individual pipes.
9. The storage area shall be cleaned and is at an appropriate height from the ground level. Separate areas
in the storage zone must be marked for different materials.
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10. Whenever heavy or bulky material is to be moved, the material handling needs will be evaluated in
terms of weight, size, distance, and path of movement.
7. Material Inspection
For materials to be inspected after receiving at the site, the following points are to be followed:
Each material item shall be allotted a distinct and separate reference number and mentioned on the
material requisition. Make sure that material is approved/examined by the consultant and QA/QC and
associated documents/test certificates are approved.
The store in-charge shall ensure that all approved supplies be delivered to the site as per the approved
material submittal; with the manufacturer’s seals, labels, or other proof of origin intact. These labels
and seals shall not be removed until the material is required for use and shall be retained for
inspection by the consultant and QA/QC.
The store in-charge shall initiate material inspection for all incoming material to QA/QC and the
material shall be inspected against reference documents and as per approved material submittal.
Moreover, the physical condition of the material shall be checked. Afterward, an INR shall be raised by
QA/QC to the consultant and an inspection will be carried out by the consultant.
Materials that do not conform to the given specification/approved material submittal, shall be
rejected. Any discrepancy or damages will be notified and reported for further action.
For any materials inspection (especially pipes, fittings, other accessories), the items shall be segregated
as per their type/sizes and placed items separately in racks or on different pallets.
Each rack/pallet shall have an identification posted on a laminated paper with the description of the
items clearly written on it.
There shall be appropriate spaces between the pallets so that the engineer/inspector can freely go
around them and inspect the materials thoroughly.
Staking the materials all over each other & in one corner is strictly not allowed.
7. Resources
7.A Tools and Equipment
The job will be carried out by manual means. The following are the types of tools identified for works:
Measuring Tape.
Pipe cutter
Marker
Copper soldering unit
Copper threading tool
Jointing Torch
Scaffolding and ladder
Plumber standard toolbox kit.
PPE (Hand gloves, face masks, safety goggles)
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Safety harness (for high-level work)
All testing equipment and measuring tools to be used shall have a valid calibration certificate prior to
usage.
All lifting equipment and machines shall be 3rd party verified with valid certificates
7.B Materials
Material includes but is not limited to the following.
• Copper tubes and fitting as per BSEN 1057, class X
• Approved copper pipes and fittings for Hot and Cold water supply.
• ERW sleeves
• Pipe support
Item Description:
Copper pipes: size range from 15 dia. to 159 dia. mm
Fittings: size range from 15 dia. to 67 dia. mm
Fittings: Size range above 67 dia. mm
Brazing and soldering
a. The material shall be used after being approved through Material Submittals.
b. All material to be used shall conform to the project specification and authorities regulations (where
required).
7.C List of Manpower
Construction Manager
Site Engineer
QA/QC Engineer
HSE Officer
Supervisor
Foreman
Pipefitters/Installers
Surveyor
Helpers
Forklift Operator
Certified welders
Note: Certificate shall be presented at the time of commencing installation.
8. Mobilization
A. Preparation and Planning
Precautions, manpower, and equipment are available before the commencement of work. The Site
Team shall make sure that access roads are always clear from any obstruction and the site is always
accessible.
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B. Site clearance
Before commencing the work, the area shall be cleared of all debris, materials, or other obstructions.
C. Traffic Management
The Site Team with the assistance of the Safety Officers shall coordinate logistics and materials
movement through the site following the direction and road signs displayed on site. The required
diversion routes shall be marked on drawings including the required traffic signs.
The Work Permits and Operator Certificates shall be compiled and files for reference by authorized
personnel.
Temporary traffic signs, barriers, and flagmen will be deployed to control traffic flow in accordance
with and Traffic Management of the HSE Plan.
At the end of each ramp, there will be a transition area to give the driver the opportunity to watch the
access roads before joining thereto.
D. Pre-construction Safety Meetings:
The meeting shall be scheduled prior to the beginning of the work and before any Subcontractor starts
on the project.
Safety awareness meetings will be conducted every working day morning/every other day to brief the
workforce on the safety prevention measures. The equipment check for safety shall be recorded/
documented during the daily Safety Awareness Meeting.
Traffic safety will be discussed to emphasize these meetings.
Each worker will be instructed to follow specific safety requirements related to his trade. They will be
required to follow installed safety signs, observe barricades and use PPEs. The safety team will perform
hazard risk analysis by identifying all steps, hazards identified in those steps, with a focus on the
relationship between the work task, the tools, and the work environment. After identifying
uncontrolled hazards; The contractor will take steps to eliminate or reduce them to an acceptable risk
level.
General Contractual Safety, Health, and Environmental requirements:
Roles of the contractor, subcontractors, authorized representatives, and all project workers.
Accident reporting requirements.
Specific details of the work to be performed along with the use of personal protective equipment.
Emergency procedure.
E. Operating Procedures:
A site investigation has to be carried out to develop safety precautions and measures prior to the
commencement of the work. After such investigation, relevant signboards will be displayed and
barricades will be installed where and as necessary, such as but not limited to the following:
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Relevant information, advanced signs, warning, and mandatory signs will be placed as required.
A radio communication system would be used where normal communication is impossible.
After completion of the work, safety cones and barricades have to be removed accordingly.
9. Methodology-Hot and cold water copper piping installation
The below methodology is based on the manufacturer’s method statement which is included in the
approved material transmittal:
Supervisor/Foreman will carry out the marking routing of copper pipe for hot and cold water supply
pipes as per approved drawings. If there is any discrepancy or difficulty in executing the work, it is to
bring to the notice of the Engineer for corrective action.
Cutting and chasing of pockets for copper pipes, to be done by means of the cutter. If a hacksaw is
used to cut the pipe, a fine-toothed blade shall be used.
Jointing of copper pipes; Clean the outside surface of the pipe and inside surface of the fitting socket,
the reliability of the soldered joint is influenced by the type of flux used. Yorkshire flux and traditional
craftsman flux are specially formulated for jointing copper pipes with Yorkshire integral solder ring
fitting.
Insert the pipe into the fitting until it reaches the pipe stop, then wipe off any excess flux. Then heat
the assembled joint until a complete ring of solder appears at the mouth of the fittings.
After jointing allows the joint to cool without disturbance, clean the joint generally, wiping off any
external flux residues, this will prevent unsightly stains or corrosion of pipework.
Threaded connection; jointing washer should be used when installing fittings with parallel connector
thread, a male thread connector a small quantity of inert jointing compound or PTFE tape should be
applied to the male thread before installing the fittings. As per the manufacturer’s recommendation,
the jointing compound should comply with
BS 6956 Part 5 and be WRAS listed. PTFE tape for water and general application should comply with BS
7786.
The copper pipes and fittings for hot and cold water supply to be assembled in position using the
torch.
The assembled copper hot and cold water supply pipes and fitting assembly are to be placed in
position by means of a clamp and supports at a specified interval and at the change of direction. The
hydro test will be done in coordination with the consultant prior to starting the wall packing.
The entire assembly is to be tested with a head of 1.5 times the working pressure of the system.
Due care to be taken to ensure that the level of the hot and cold water pipes assembly is not disturbed
during packing, plastering, and tiling, and contractors representative will ensure, throughout the
mortar packing process, that no pipes get damaged.
In case of the hot and cold water pipes assembly is running expose above the false ceiling or on the
roof, the copper pipe will be used and proper access for maintenance is to be provided.
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9.1 Cut tube square
Cut to the exact length required using a tube cutter or hacksaw If a hacksaw is used, a sawing fixture
should be used to ensure square cuts. Remove all inside and outside burrs with a reamer, file, or other
sharp edge scraping tool. If the tube is out of round it should be brought to true dimension and
roundness with a sizing tool.
9.2 Clean tube end and inside surface of the fitting
The joint surface areas should be clean and free from oil, or oxide contamination. Surfaces may be
properly cleaned for brazing by brushing with a stainless steel wire brush or by a stiff rubbing with an
emery cloth.
If oil or grease is present clean with a commercial solvent. Remember to remove small foreign particles
such as emery dust, by wiping with a clean dry cloth. The joint surface must be clean.
9.3 Flux application
While flux is used for most applications. Black flux is helpful for long heating cycles or localized heating
with induction. It is also used when brazing stainless steel.
Flux goes through physical changes during heating and turns clear at about 1100°F/593°C. This is an
indication that parts are close to the brazing temperature. Stir Flux before use. If the flux is dried out
add a small amount of water unit flux reaches a paste consistency
9.4 Adjust torch flame
Oxygen/acetylene- For most brazing jobs using oxy-acetylene gases, a slightly carburizing or neutral
flame should be used. The neutral flame has a well-defined inner core. Avoid an oxidizing flame.
Air/acetylene using inferno® swirl Combustion Tips-Brazing with air/acetylene is a popular alternative
to oxygen mixed fuel gas. The fuel gas flow aspirates air into a mixer that contains an internal vane
that spins the gas to improve combustion and increase flame temperature.
If the tank has a delivery pressure gauge, set the delivery pressure to 14-15 psi. If the tank has only a
contents gauge delivery pressure is preset at the factory. Open the regulator adjusting screw all the
way by turning it clockwise until it bottoms.
Open the torch valve-opening the torch valve for about ¾ of a turn will provide sufficient fuel gas
delivery. Do not try to meter pressure (reducing the flame) by using the torch handle valve. If a higher
or lower flame is required, change to a different tip size.
Other fuel gases-alternate fuel gases such as propane, propylene, and neutral gas can be mixed with
oxygen for brazing. Refer to the harris equipment catalog or website for equipment and setting
information.
9.5 Heating the joint
Always keep the torch in short motion.
Start heating the tube, by first applying the flame to a point just adjacent to the fitting.
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Work the flame alternately around the tube and fitting until both reach brazing temperature, before
applying the brazing filler metal.
When the flux is used. it will be a good temperature guide. Continue heating the tube until the flux
passes the “bubbling” temperature range and becomes quiet, completely fluid, and transparent.
Watch for this on both sides of the joint to ensure even heating
Direct the flame from the tube to the fitting. When the alloy is applied it should quickly melt and flow
into the joint.
Sweep the flame back and forth along the axis of the assembled joint, tube, and fitting to reach and
then maintain uniform heat in both parts.
9.6 Apply the brazing alloy
Feed the alloy into the joint between the tube and the fitting. Only after the base metals have been
heated to brazing temperatures should the filler metal be added. At the time flame may be deflected
momentarily to the tip of the filler metal to begin the melting process.
Always keep both the fitting and the tube heated by playing the flame over the tube and the fitting as
the brazing alloy is drawn into the joint. The brazing alloy will diffuse into and completely fill all joint
areas.
Do not continue feeding brazing alloy after the joint area is filled. Excess fillets do not improve the
quality of the dependability of the braze and are a waste of material.
9.7 Making vertical alloy up joints
Heat the tube first, then apply heat to the fitting. It is important to bring both pieces up to
temperature evenly. Keep the flame directed towards the fitting. If the tube is overheated, the brazing
alloy may run down the tube rather than into the joint.
9.8 Clean after brazing
All flux residue must be removed for inspection and pressure testing immediately after the brazing
alloy has set quench or apply a wet brush or swab to crack and remove the flux residue. Use an emery
cloth or a wire brush, if necessary.
9.9 Separate a brazing joint
First, clean the joint thoroughly, then flux the visible alloy and all adjacent areas of the tube and
fittings. Next, heat the joint (tube and fittings) evenly, especially the flange of the fitting. When brazing
alloy becomes fluid throughout the joint area, the tube can be easily removed. To re-braze, the joint,
clean the tube end and the inside of the fitting
and proceed as directed to make a new brazed joint.
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9.10 Nitrogen purge
During braze heating, an oxide scale forms on the inside of the copper tube. These dark scales flake off
and are carried by refrigerant and can potentially clog small orifices.
For HVAC/R and medical gas, installations flow nitrogen through the tube during brazing to prevent
internal scale information. Use a low flow rate to avoid excess pressure inside the tube. A small hole at
the line end will allow the nitrogen to escape.
9.11 Pipe penetrating the walls and slab
Where pipe passes through floor, slabs, walls, the roof, or penetrate any other form of construction,
pipe sleeve shall be supplied and accurately placed in the building surface. The pipe sleeve shall be
sized to provide 15 mm clearance around the pipe to be installed or, where the pipe is to be thermally
insulated or otherwise covered, 15 mm clearance around the covering surface. This clearance space
shall be packed with approved fire resisting material and sealed at both ends with waterproof and fire
retardant mastic.
Sleeves shall be of material compatible with the pipe and of length to finish flush with the finished wall
and were passing through floors of length to protrude 6mm above and below the finished floor and
the underside level (soffit).
Roof sleeves shall be provided with water-shedding external cowls and flashing.
Water protecting pipe sleeves through floors shall be supplied and fixed in the following location:
In mechanical plant rooms
In kitchen areas, toilets and cleaners rooms
In slabs over mechanical and electrical plant rooms
On all floors having a waterproof membrane
The pipe sleeves shall be galvanized mild steel pipe set to extend for the full thickness of the structural
element and 50mm minimum above finished level.
Wall and floor plates:
Where pipe penetrates walls, floors or ceilings, (except at plant, equipment, and cleaners rooms or
other storage areas) split type chromium-plated steel wall plates shall be fixed to closely fit the
building surface and provide a neat appearance.
9.12 Supports and hangers
All supports system shall be of the correct size, strength and allow for expansion, contraction, and
anchoring of the piping systems. Full details of hangers and supports proposed for use shall be
submitted before fixing commences.
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Vertical drop shall be properly restrained and supported to prevent offset and sway. Piping at all
equipment and valve positions, and at main junctions, shall be adequately supported to prevent any
distortion or transmission of the train to connected equipment or valves.
Brackets and supports shall be so arranged and set out to allow sufficient access for adjustment,
maintenance, and removal of equipment, valves, and accessories with the minimum of dismantling
and without the need for additional temporary supports after items are removed.
A proprietary support system for all pipework may be used to achieve technical and visual
compatibility of supports subject to acceptance by the Engineer.
Piping shall be supported by the use of rollers and chairs, guides, clips, or hangers fixed at interval
scheduled. Where two or more pipes are to be carried out by a single support, the support spacing
shall be for the shorter interval.
All mild steel sections, plates, clamps, and fixing devices for fastening hangers and supports shall be
provided by the contractor.
Hangers for cold piping required to be thermally insulated shall be provided with high-density foam
insulation (reinforced where necessary) bearing inserts capable of withstanding the clamp
compression and allowing the hanger to support the pipe without metal-to-metal contact.
Insert shall be of the same thickness as the thermal insulation required and valve extended cylindrical
insulation shield of galvanized sheet steel or glass fiber reinforced plastic of not less than 2mm
thickness with adequately sealed joints to maintain vapor barrier where applied.
Support and hangers for mild steel piping shall be ferrous. Supports and hangers for copper piping
shall be non-ferrous, or alternatively may be ferrous with an insert separation liner to prevent
electrolytic action. Supports and hangers for chromium-plated or stainless steel piping shall be
chromium-plated.
10. Health, Safety and Environment
I. Risk Assessment:
Risk Assessment/Job Hazard analysis as provided/attached in the method statement for water piping
copper (hot and cold) installation.
II. Protective and Safety Equipment
All workers involved shall be equipped with adequate PPE as stated below:
• Safety helmet with company logo
• Safety boots, safety goggles, hand gloves
• High visibility vest
• Welding specific PPE (Welding vest, mask, gloves, visor)
• Twin tail harness, max 1 m long (when working on height)
All special PPE (Harness) is considered as a last resort when it cannot engineer, administratively
eliminate, or guard against hazards.
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TITLE:
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III. Information to Personnel
• Safety Induction
• Job Training
• Superintendents
• Notices/Memos
• Toolbox Talks
• Briefings before starting work
IV. Emergency Procedures :
The contractor shall provide first aid kits on site for handling light injuries.
In the event of an emergency, all workers will be asked to evacuate and assemble at the “ASSEMBLY
POINT” and wait for further instruction from supervisors.
11. Quality Assurance and Quality Control for Method Statement for Water Piping Copper (Hot and Cold)
11.a Quality Assurance Requirements
The contractor shall provide the required documents for the consultant’s approval prior to initiating
the execution of this activity as per project specification.
The quality control requirement shall include related QCP’s, ITP’s and other related documents as
applicable.
Applicable codes and standards for materials are project specifications and contract requirements.
11.b Quality Assurance Process
The contractor shall notify the engineer prior to the start of the activity and comments from the site
Instruction will be complied with the satisfaction of the consultant.
12. Follow up and Evaluation
Follow up on quality performance shall be carried out through an in-house monitoring system such as
progress reporting to the planning department, daily, weekly and monthly reports generated by the
planning department to closely
monitor site performance in general and reflect on quality performance in specific.
All the above shall be conducted in close coordination with the quality department to monitor any
deviations from the normal quality requirement and induce corrective actions whenever required to
eliminate non-conformance or
quality deviations.
All remedial actions to be taken, if any, shall take into account the official schedule which is to be used
as a guideline for performance and most importantly under the close supervision of the quality control
department.
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13. Records
• Checklists (CL)
• Inspection Request (INR)
• Inspection and Test Record (ITR)
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METHOD STATEMENT FOR
SPLIT AC INSTALLATION
SR. EFFECTIVE REV. MSS MANAGER MSS PROJECT CLIENT
CLIENT QA/QC
NO. DATE NO. QA/QC MANAGER SUPERVISOR
SPLIT AC INSTALLATION
1. PURPOSE
This method statement of split AC units installation ensures that specified materials are installed and
agreed procedures are implemented during the execution of work. This MST defines the
documentation and responsibilities for controlling the project quality and HSE requirements.
2. Scope
This method statement is intended to outline the activities and the methods used for the installation
of split Air Conditioner (AC) units. All activities will be carried out in accordance with the contract
details and in full compliance with the project specifications and references. The split Air Conditioner
(AC) units methodology covers the equipment setting procedures and installation technique utilizing
the method statement of pipes & fittings installation as well as the sequence of operation as set out in
the given specification and approved drawings for the HVAC system.
After the system installation has been completed, the entire system shall be checked, inspected, and
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functionally tested by qualified and approved 3rd party specialists, as per the manufacturer’s
recommended procedures.
The installation of split units has many advantages over traditional air-conditioners. The most obvious
benefit is the quiet performance of the split unit system. The part of the air conditioner that makes the
most noise is the compressor and the fan that cools the condenser. In a split system, the compressor
and the fan for the condenser are located outside of the room being cooled and therefore the major
sources of noise are removed.
3. References
Project Specifications
AHRI
ASHRAE 15 and 34 and 62.1 Sections 4, 5, 6 & 7
NFPA 70
Manufacturer’s Recommendation
Approved Material Submittals
Approved Shop Drawings
4. Abbreviation
HSE Health, Safety and Environment
QA/QC Quality Assurance and Quality Control
MST Method Statement
RA Risk Assessment
ITP Inspection and Test Plan
PQP Project Quality Plan
INR Inspection Request
PPE-Personnel Protective Equipment
MEP-Mechanical, Electrical & Plumbing
STARRT-Safety Task Analysis Risk Reduction Talk
AHRI-Air Conditioning, Heating and Refrigeration Institute
ASHRAE-American Society of Heating, Refrigerating, and Air-Conditioning Engineers
NFPA-National Fire Protection Association
AC-Air Conditioner
5. Responsibilities
A. General
1. Project Manager (MEP) will be responsible to manage, execute, complete and handover the
construction activities within approved budgets and resources in compliance with project
requirements as specified in project specifications. He will be overall in charge of implementing
Method Statement in accordance with QA/QC and HSE requirements.
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2. Construction Manager will be responsible for managing construction activities and will lead and
communicate site teams, subcontractors and vendors in assisting them from working within project
schedule.
3. HSE Manager will be responsible to plan, coordinate and implement issues and directives within the
organization. He ensures safe environmental working conditions for all employees.
4. QA/QC Manager will be responsible for supporting the project team in implementing and maintaining
Quality Management System for the project through PQP, ITP, Method Statement of Split AC Units
Installation, and procedures in compliance with project specifications, codes and standards.
5. HSE Officer will ensure enforcement of safety procedures in accordance with the approved HSE Plan.
Will be closely monitoring the site engineer’s strict implementation of the Method Statement of Split
AC Units Installation and Risk Assessment, the use of proper tools and equipment to maintain safety,
certifications of equipment and their adherence to safety regulations, reporting of any unsafe work or
stopping work that does not comply with HSE procedures.
6. Site Engineer will be responsible for carrying out all construction related activities with compliance to
HSE and QA/QC requirements as per contract specifications, drawings/documents, codes and
standards.
7. QA/QC Engineer will be responsible for conducting inspections as per PQP.
8. Supervisor/ Foreman will be responsible for coordinating all works and workers relate to job.
9. Electrician / other tradesmen will be responsible in assisting his superiors during all construction work
related activities following HSE and QAQC requirements.
10. Store in-charge receives and inspects all Incoming materials and reconciles with documents; processes
and distributes documentation; reports, documents and tracks damages and discrepancies.
6 .Handling, Storage and Transportation
• During transport, handling, and storage special care shall be taken not to damage the materials.
Materials shall be cleaned from any foreign matter deposited during transport.
• All material storage locations should be on suitably firm, level ground, free from damaged material
with adequate access for construction vehicles and/or lifting equipment.
• On receipt of equipment and accessories at the site, necessary precautions shall be taken for
unloading, shifting, and storage as follows:
• Any equipment and accessories deliver at the site shall be carefully off-loaded by deploying
necessary manpower in such a way that no damage shall cause to equipment.
• Equipment and accessories shall be inspected, handled, and stored properly upon receipt at the site.
• Equipment and accessories shall be stored in a place free of water, moisture, and dust and
adequately covered to avoid any kind of damages. All materials to be stored are strictly in accordance
with the authority’s requirements/manufacturer storage recommendation.
• Equipment and accessories shall be transported to the workplace using adequate manpower.
• While unloading, shifting, and storage, it should be ensured that there are no transit damages.
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• Any discrepancies, damage, and etc. found to the materials will be notified and reported to QA/QC
Engineer and Project Engineer for further action.
• Materials found not suitable for site use should be removed from the site immediately.
• Protect from watermarks as any damage or watermark is not allowed during installation.
8. .Material Inspection
For materials to be inspected after receiving at the site, these points are to be followed:
• Each material item shall be allotted a distinct and separate reference number and mentioned on the
material requisition.
• Make sure that material is approved/examined by the Consultant and QA/QC and associated
documents/test certificates are approved. ·
• The Store In-charge shall ensure that all approved supplies be delivered to the site as per the
approved material submittal; with the manufacturer’s seals, labels, or other proof of origin intact.
• These labels and seals shall not be removed until the material is required for use and shall be
retained for inspection by the Consultant and QA/QC.
• Store In-charge shall initiate material inspection for all incoming material to QA/QC and the material
shall be inspected against reference documents and as per approved material submittal.
• Moreover the physical condition of the material shall be checked. Afterward, an INR shall be raised
by QA/QC to the Consultant and inspection will be carried out by the Consultant.
• Materials, which do not conform to the given specification/approved material submittal, shall be
rejected. Any discrepancy or damages will be notified and reported for further action.
• For any materials inspection, the items shall be segregated as per their type/sizes and placed items
separately.
• Each item shall have an identification posted on a laminated paper with the description of the items
clearly written on it.
• There shall be appropriate spaces between the material items so that the engineer/inspector can
freely go around them and inspect the materials thoroughly.
• Stacking the materials all over each other & in one corner is strictly not allowed.
7. Resources
7.A. Tools and Equipment
Tools
a. Standard mechanical toolbox kit
b. Standard electrical toolbox kit
c. Pipefitter toolbox with complete hand tools
d. Measuring tape
e. Digital multimate (electrical)/meager
f. Electric drill with bits and grinder.
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g. Open and box type wrench/spanners set
h. Chalk line/marking pen
i. Measuring tape
j. Ball hammer and cold chisel
k. Screwdriver set
I. Cleaning brush
m. Level bar/plumb bob
n. Step ladders/movable scaffolding
Equipment
a. 2-3 Tons Forklift.
b. Hydraulic Trolley
c. Lifting Equipment (Shackles, Pad Eye, and Belt) – Third Party Certified.
d. Scissor Lift
e. Testing Equipment includes test pump and test manifolds, calibrated pressure gauges.
Note:
• All testing equipment and measuring tools to be used shall have a valid calibration certificate
prior to usage.
• All lifting equipment and machines shall be 3rd party verified with valid certificates.
7.B. Materials
Split AC Units
a. The material shall be used after being approved thru material submittals.
b. All materials to be used shall conform to the project specification and authorities regulations (where
required).
7.C. List of Manpower
Construction Manager
Site Engineer
QA/QC Engineer
HSE Officer
Supervisor
Foreman
Welders/Installers
HVAC technician
Surveyor
Helpers
Trailer drivers
Mobile Crane/ Crane Operator
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Forklift Operator
Riggers
8. Methodology-Split AC Units Installation
8.A. Pre-installation
All relevant documentation, approved shop drawings, and material applicable to a particular section of
works will be checked by Site Engineer prior to commencement of work.
Ensure that material received is in compliance with the project specifications/authorities regulations.
Ensure delivered equipment is as per approved Material Submittal and approved equipment schedule.
Ensure that all required materials and accessories are delivered, inspected, and approved by
consultants and are readily available at the site to carry out the work.
All relevant documentation (includes MST-Method Statement of Split AC Units Installation and RA are
approved, obtain necessary work permits, fill up STARRT cards after completion of daily toolbox talk),
will be checked by Site Engineer prior to commencement of work.
The Site Engineer/Site Supervisor will give necessary instructions to tradesmen (Mechanical) and
provide necessary approved construction/shop drawings.
The Site Engineer/Site Foreman will check that proper tools and equipment are available to carry out
the work and are in compliance with contract specifications.
The Site Engineer will explain to his team about HSE precautions to be observed.
Ensure proper storing/handling of the equipment without damaging the surface.
Before starting the installation, ensure that area has been surveyed & coordinated.
Ensure all installation and testing of pipework and ductwork have been completed and approved by
the consultant, prior to proceeding in the connection.
Relevant documents or certificates shall be presented at the time of inspection if required by the
consultant.
Permission to start or civil clearance prior to installation has been given by the main contractor.
Installation activity shall only commence when all associated works by the civil have been completed.
Safe access shall be provided by the contractor thru work permits in coordination with the safety in
charge at the site.
Check for other services, making sure that there is no interference between each service & adequate
access to work and for future maintenance can be maintained.
8.B. Installation
Supports and Hangers Installation
Install supports or brackets for split AC units as per specification, approved shop drawing, and site
conditions for each individual case (i.e. slab, floors, and walls, etc.).
Supports are to be fixed at correct levels checking the bracket material is compatible with the
installation.
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In line equipment is to be independently supported from the main structure.
Lift up the ceiling suspended split AC units using the third-party certified shackles, pad eye, and belt
(instead of the crane).
9 .Split AC Units Indoor Installation
Indoor type split units can stand or lie on the floor, or hang from the ceiling or wall. Allow space for
wiring, piping, and service units.
For the installation of horizontal right conversion of the unit with slope coil installation to be
followed.
For optimum condensate drainage performance in horizontal installation, the unit should be
leveled along its length and width.
In a horizontal installation, the unit must not be installed with access panels facing up or down. All
other units are factory built for horizontal left installation suspending unit from the ceiling, dimples
in casing indicate the suitable location of screws for mounting metal supports.
Align holes with tubing connection and condensate pan connections and reinstall access panel and
fitting panel. Make sure liquid and suction tubes are prevented from air leaks and cabinet
sweating. Install after brazing.
For air duct connection, ensure to connect the supply air duct over the outside of the flange
provided on the supply air opening. Secure the flange using the approved fasteners for the type of
duct used and seal the duct-to-unit joint. If return air flange is required, install factory authorized,
use flexible connectors between ductwork and unit to prevent transmission of vibration. When the
electric heater is installed use heat-resistant material. The connector between ductwork and unit
at discharge connection. Ductwork passing through unconditioned space must be insulated and
covered with a vapor barrier.
Establish the reference level/datum point from where measurement will be made to the position
of the service.
Installed approved supports, vibration isolators, brackets, and anchor fasteners as per project
specifications, material submittal approval, and manufacturer instruction.
Permanent, accessible and sufficient clearances to be provided for servicing and maintenance of
the equipment as per approved shop drawing and manufacturer’s instruction.
All installation and construction works require will be undertaken in accordance with manufacturer
instruction and project requirements.
Maintain proper bottom of indoor split AC units as per approved coordination drawing.
Supervisor to ensure that there are no dents, distortion, or any possible damage during
installation.
Condensate Drain Pipe (CDP) installation should be as per approved shop drawings, and project
specifications.
After completion of split AC units installation work, identification of equipment will be performed.
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See Detailed Indoor Split AC installation procedure and wiring diagram-“Split AC Unit
Manufacturer’s Installation Detail” (attached)
The Site Engineer/Foreman ensures the cleanliness of the area.
10 .Split AC Units Outdoor Installation
Ensure the proper location of the unit as per the approved shop drawing.
Ensure that vapors and liquid tube diameters are appropriate to the capacity of the unit.
Leave some slack between structure and unit to absorb vibration.
Ensure that tubing insulation completely surrounds the vapor tube.
If required use hanger straps that are 1 inch wide and conform to the shape of tubing insulation.
Insulate hanger strap from insulation by using metal sleeves bent to conform to the shape of
insulation.
Unit shall be mounted to pad; tie-down bolts should be used and fastened through knockout
provided in the unit base pan. Arrange supporting members to support the unit and minimize
transmission of vibration.
For the floor/roof-mounted outdoor unit AC installation, close coordination with the civil team is
required for the concrete base (detail is to be provided in the related shop drawing and ensure
approval prior to installing the floor-mounted outdoor unit).
For the wall-mounted outdoor unit AC installation, please see the attached manufacturer’s
installation detail.
When installing allow sufficient space for airflow clearance, wiring, refrigerant piping, and service.
Permanent, accessible and sufficient clearances to be provided for servicing and maintenance of
the equipment as per approved shop drawing and manufacturer’s instruction.
All installation and construction works require will be undertaken in accordance with manufacturer
instruction, project requirements.
Supervisor to ensure that there are no dents, distortion, or any possible damage during
installation.
After completion of Split AC Units installation work, identification of equipment will be performed.
Detailed Indoor Split AC installation procedure and wiring diagram-“Split AC Unit Manufacturer’s
Installation Detail”.
The Site Engineer/Foreman ensures the cleanliness of the area.
11. Split AC Units Wiring Installation
Before wiring, confirm the rated voltage of the unit as shown on its nameplate, then carry out the
wiring closely following the wiring diagram.
Provide a power outlet to be used exclusively for each unit, with a power supply disconnect and
circuit breaker for overcurrent protection provided in the exclusive line.
Ensure the installation of an electrical isolator (disconnect switch) for outdoor units and DP switch
for indoor units.
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To prevent possible hazards due to insulation failure, the unit must be grounded.
Each wiring connection must be done tightly and in accordance with the wiring system diagram.
Wrong wiring may cause the unit to malfunction or become damaged.
Do not allow wiring to touch the refrigerant tubing, compressor, or any moving parts of the fan.
Ensure to comply with local codes on running the wire from the indoor unit to the outdoor unit
(size of wire and wiring method, etc.).
Each wire must be firmly connected.
Be sure to connect the power supply line to the outdoor unit. The indoor unit draws its power
from the outdoor unit.
Ensure field wiring complies with local regulation and electrical codes or as specified in the
specification and voltage to the system is within limits. Operation of unit on improper line voltage
constitutes abuse and could affect the units” reliability. Do not install the unit in the system where
voltage imbalance may fluctuate above or below permissible units.
Detailed wiring procedure and wiring diagram is shown in ” Split AC Unit Manufacturer’s
Installation Detail”.
12. Inspection and Testing
After completion of the work, the Site Engineer & Supervisor who perform an activity are required to
raise an INR with complete attachment & information regarding the scope of the inspection, including
necessary drawings highlighted to show the scope of the inspection. He shall systematically check and
inspect their work. The inspection shall be performed according to a typical checklist and approved
Inspection and Test Plans (ITP).
After Site Engineer & Supervisor completed their inspection and testing, INR shall be submitted to
QA/QC Department who shall check and process the documents to have completed work inspected by
Supervision Consultant for their approval.
Testing/running test of equipment installed shall be as per manufacturer’s instruction and witnessing
by the supervision consultant prior to final approval. Details start-up and commissioning procedures
are to be submitted in a separate method statement.
Manufacturers should be present during the start-up and commissioning of the equipment.
Raise INR for final inspection if no problem is encountered.
Note: INR must be processed and submitted to the supervision consultant 24 hours before the actual
inspection and/or witnessing of the activity.
13. Health and Safety Analysis
A. Risk Assessment
Refer to Risk Assessment/Job Hazard Analysis.
B. Permit and Licensing Requirement
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The required permit to work shall be obtained prior to commencement of work. This shall be
coordinated with HSE. Site interface permits to be taken from other contractors before placing pipe at
tie-in point to reconfirm IL and coordinates.
C. Pre-Start Safety Briefing Arrangements
C.1 Protective and Safety Equipment
All workers Involved shall be equipped with adequate PPE as stated below:
• Safety Helmet with Company Logo
• Safety Boots
• High Visibility Vest
• Safety Goggles
• Hand Gloves
• Coveralls
• Proper safety harness
C.2 Information to Personnel
• Safety Induction
• Job training-All the personnel involved in this task shall be provided training and only trained
personnel shall be authorized to work around this area.
• Toolbox talks
• STARRT Card
C.3 Special Safety Requirements:
• All necessary personal/protective equipment (PPE), as well as harness, be provided.
• Rigging Team, wearing distinctive vests, shall be assigned to help operators maneuver their
equipment.
• The equipment operators shall possess the required licenses and certificates.
• The required permit to work shall be obtained prior to commencement of work.
• The project safety officer is responsible along with the project zone site engineer for ensuring that all
operations are carried out with due regard to the safety of all project personnel & property.
• Working at height to be monitored with due care.
• In case of working at night, please refer to Method Statement for Night Works.
• Contractor must provide a safe place of works, with access and egress. Provide a safe working
environment that is without risk to health.
14. Quality Assurance and Quality Control for Method Statement of Split AC Units Installation
14.A. Quality Assurance Requirements
• The contractor shall provide the required documents for the consultant’s approval prior to initiating
the execution of this activity as per project specification.
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TITLE:
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• The quality control requirement shall include related QCP’s, ITP’s and other related documents as
applicable.
14.B. Quality Assurance Process
• The contractor shall notify the engineer 24 hours in advance prior to the start of the activity.
• The contractor shall consult the public utility authorities not less than one month before it is
proposed to commence work to ascertain whether any underground installations will be affected by
the proposed work, in which event the contractor shall make all necessary arrangements with the
public utility authorities to safeguard the installation.
14.C. Follow up and Evaluation
• Follow up on quality performance shall be carried out through an in-house monitoring system such
as progress reporting to the planning department, daily, weekly and monthly reports generated by the
planning department to closely monitor site performance in general and reflect on quality
performance in specific.
• All the above shall be conducted in close coordination with the quality department to monitor any
deviations from the normal quality requirement and induce corrective actions whenever required to
eliminate non-conformance or quality deviations.
• All remedial actions to be taken, if any, shall take into account the official schedule which is to be
used as a guideline for performance and most importantly under the close supervision of the quality
control department.
14.D. Records
• Checklists (CKL)
• Inspection Request (INR)
• Inspection and Test Record (ITR)
16.Attachments
HSE Risk Assessment for Installation of Split AC Unit
Inspection and Test Plan for Installation of Split AC Unit
Checklist for Installation of Split AC Unit
Split AC Units Manufacturer’s Installation Detail
Split AC Unit Manufacturer’s Installation Detail –
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METHOD STATEMENT FOR
FIRE PROTECTION
EQUIPMENT INSTALLATIONS
SR. EFFECTIVE REV. MSS MANAGER MSS PROJECT CLIENT
CLIENT QA/QC
NO. DATE NO. QA/QC MANAGER SUPERVISOR
FIRE PROTECTIONBEQUIPMENT INSTALLATIONS
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1. Scope of Work
This Method Statement for Fire Protection Equipment defines the execution for the installations in
accordance with the relevant reference standards, project specifications, approved shop drawings, and
health, safety & environment (HSE) requirements. The installation contractors are required to follow
this method statement at all times during the whole working period. The subcontractor shall ensure
that the safe work systems resulting from the Risk Assessments are employed throughout the works as
described. The Construction Manager and Safety Manager have the responsibility for ensuring that the
method statement procedures are adhered to and are verified using the SADD’s.
2. Purpose of the Method Statement for Fire Protection Equipment Installations
The purpose of this Method Statement for Fire Protection Equipment Installations is to provide
instruction for the installation of fire protection equipment.
This work is specifically for the exposed wall-mounted/ floor-mounted, Internal wall and floor
mounted works necessary for the proper execution and timely completion of the project, in line with
approved construction drawings and project requirements.
3. Definitions and Abbreviations
The following definitions and Abbreviations are used:
BS British Standard
HSE Health Safety and Environment
IFC Issued For Construction
ITP Inspection and Test Plan
MAR Material Approval Request
MEP Mechanical Electrical Plumbing
MS Method Statement
NCR Non Compliance Report
NFPA National Fire Protection Association.
PE Project Engineer
PPE Personal Protective Equipment
QC Quality Control
RA Risk Assessment
SADDS Site Activity Day Diary Sheets
4. Reference Standards
NFPA 10 – 2013 For Portable Fire Extinguisher
NFPA 13 – 2016 For Installation of Sprinkler System
NFPA 14 – 2016 For Stand Pipe & Hose Systems
NFPA 24 – 2016 For The Installation of Private Fire service Mains and Their Appurtenances
NFPA 25 – 2016 Standard for the Inspection, Testing, and Maintenance of Water-Based Fire Protection
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NFPA 1961-2013 For Fire Hose
NFPA 1963 – 2014 For Fire Hose Connections
5. Reference Documents
Material Approval Request
Project Specifications
IFC Drawings
Project Quality Plan
Quality Inspection Management
HSE Plan
Environmental Management Plan
Sustainability Management Plan
6. Health, Safety and Environment
6.1 Health and Safety
All site operatives will be required to undergo site safety Induction and suitable training prior to
undertaking any site construction works. As a minimum, the following PPE will be provided in addition
to that identified in the Risk Assessment.
a) Safety Glasses.
b) Safety Helmet
c) Safety Shoes
d) Hand Gloves
e) High Visibility Vest
f) Safety Harness
g) Coverall
The Health and Safety considerations included in the Method Statement for Fire Protection Equipment
Installations:
a) Issue approved Method Statement & Risk Assessment to supervisors operatives prior to the work
commencement.
b) Conduct daily task briefing and toolbox talks before starting work and record all participants by
signing an attendance sheet and recording in SADD’s
c) Obtain confirmation from the main contractor that the designated construction areas have safe
access and that all related safety precautions and safety warning measures have been implemented by
a subcontractor.
d) Provision of shaded rest areas where practical on-site and welfare facilities.
e) Provision of drinking water, toilets, and washing in stations.
f) Daily compliance of the working practices stated in the Method Statement for Fire Protection
Equipment Installations will be managed by using the SADD inspections. Daily Audits will be conducted
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by the Site Engineer and HSE Inspector throughout the duration of the works.
g) Activity-related Health & Safety.
h) Necessary permit to work system.
i) Site Specific Risk Assessment.
6.2 Environmental
The environmental threats risks issues and concerns shall also be managed using the SADD during the
works: The main environmental issues include :
a) Noise disturbance
b) Waste management
c) Lighting
d) Dust Control
7. Quality
The Inspection and Test Plan for the Method Statement for Fire Protection Equipment
Installations summarizes the specific characteristics and objectives that are to be satisfied. The Site
Construction Manager will be responsible to ensure stage-wise compliance for these operations, and
the QA/QC Engineer will carry out quality control checks and report the inspection results. The ‘Hold
Points’ are identified in the ITP.
8. Materials Delivery
All delivered materials shall be inspected on arrival at the site.
The inspection shall be advised, in advance as required by ITP.
All approvals documents and certification shall be made available for site goods received inspections at
the time of the delivery.
Material delivered on-site must be new & bear complete identification as per specification.
All materials shall be free from any defects or damages and foreign materials that will result in the
inability to install the materials and subsequent deterioration.
All materials shall be as per approved material submittal & samples.
No materials will be permitted to enter the work location without prior inspection and approval.
Materials inspection request MIR shall be issued by sub-contractor and submitted by main contractor
and materials shall be inspected and approved by Engineer’s representative prior to dispatch to site
and commencement of works.
9. Handling and Storage of Materials
All materials will be delivered to the site by truck/trailer. quantities of materials stored on-site shall not
exceed 2 Weeks of planned production. All incoming materials will be off-loaded by Boom truck or
manually into storage area. Manual handling shall be up to 25Kgs.
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On receipt of fire protection equipment like landing valve, breeching inlet, portable fire extinguisher,
fire blanket, and fire hose cabinet the materials shall be handled & stored in line with the following
procedure:
a) The landing valve, breeching inlet, fire hose cabinet, fire extinguisher, fire blanket, fire hose, landing
valve cabinet, nozzles, breeching inlet cabinet delivered at the site shall be carefully off-loaded by
deploying necessary/ adequate dedicated manpower for loading and unloading materials in such a
way that no damage is caused to the same.
b) Fire hose cabinet, shall be stacked as type-wise on a flat surface free from any sharp objects and
shall be given adequate supports at all times.
c) Necessary care should be taken not to shatter the glass of breeching inlet & landing valve cabinets.
d) Ensure fire extinguishers & fire blankets are stored in a place where the maximum ambient
temperature does not exceed the temperature rating of the manufacture.
e) All the materials shall be stored in a place free of water, dust & adequately covered to avoid any
kind of damages.
f) While unloading, shifting, and storage, it should be ensured that there are no damages.
g) Delivery of materials will be checked/inspected by contractor QC Engineer to ensure all
items on delivery notes are correct prior to signing. Any shortage or damaged items should be
recorded on the delivery note and reported to the Engineer.
h) Any discrepancies, damage, and etc. found to the materials shall be notified and reported to QA/QC
Engineer.
i) Materials found not suitable for site use shall be removed from the site immediately and moves in
the quarantine zone and reported on SADD’s.
j) Raise the MIR for engineers’ approval.
10. Responsibilities for Method Statement for Fire Protection Equipment Installations
Project Manager
Responsible for providing adequate resources and ensuring that the project specifications regulations
are adhered to.
Sr. MEP Engineer
Oversee the entire MEP construction activities within the site and ensure that activities are carried out
as per the contract drawings and documents and report same in SADD’s.
MEP Construction Engineer
Supervise the subcontractor to meet the desired quality of the activities and ensure that proper work
and schedules are met.
Site Engineer
Supervise closely, the activities designated to them and ensure that all instructions and safety
procedures are followed and strictly adhered to.
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QA/QC Engineer
Conduct surveillance and inspection duties at various stages to ensure compliance to QA/QC Plan.
HSE Manager
Provides advice and support in the application of this procedure and monitors the effectiveness of the
relevant control documents.
HSE Officer/ Inspector
Ensure enforcement of safety procedures in accordance with the Main Contractor HSE Plan /
Procedures & project specifications requirement.
11 .Tools and Equipment
The following tools and equipment items have been identified for the installation of fire protection
equipment:
a) Measuring tape hand tools box ( Adjustable spanner set, cutting pliers, screwdriver set, hammer,
hacksaw frame & flat file, spirit levels).
b) Portable drilling machine.
c) Boom truck
d) Measuring tape and suitable materials for marking.
e) A-type ladder.
f) Mobile type scaffolding with wheel safety lock.
g) Electric drilling/ hammering/ grinding machines.
h) Adjustable pipe wrench.
i) Speed metal cutting machine.
j) Pipe threading machine.
k) Roll grooving machine.
I) Paintbrush.
m) Pipe vise table.
n) Hack and saw.
o) Wooden mallet.
12. Pre-Site Work
Prior to the commencement of any installation works associated with the fire protection equipment,
the MEP subcontractor will ensure that all site installation pre-conditions have been satisfied. These
include a site inspection to verify that the site condition is considered suitable for work to commence
and that the main contractor’s safety provisions have been provided and were completed by
subcontractors’ safety provisions also. E.g. Site Access Site Illumination etc.
Prior to installation, the subcontractors shall ensure that:
a) All materials and documentation relevant to a particular section of works have been checked by the
site/project engineer prior to the commencement of work ensuring that these are of the correct type
as reviewed by the client.
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b) Before commencement of any construction works, pre-inspections will be carried out on all
materials prior to being withdrawn from the storage area i.e. quantity, physical damage and
brand/make.
c) Works shall not proceed until an approved IFC shop drawing or detail is issued.
d) Safe access to work areas shall be provided and shall be approved by the competent safety person
prior to commencement of works if applicable.
e) The Site Engineer/Supervisor will also check that tool and equipment available is in compliance to
contract requirements.
f. Where the RA identifies high-risk works, a permit to work must be obtained from the safety
department and entered on SADD’s.
g) Documents required for the execution of the construction work are of the latest issued shop
drawings should have IFC stamp prior to starting the work (specifications, working drawings,
Manufacturer’s drawings, etc.)
h) Ensure that all relevant documentation i.e. ITP, installation method statement, shop drawings &
MEP coordinated drawings, etc. are available and approved.
i) Skilled manpower required for carrying out the construction work will be employed.
k) Check that proper tools and equipment are available to carry out the work and are in compliance
with contract specifications.
I) Mobilize all equipment and materials which are required for the Installation of firefighting
equipment.
m) Adequate exclusion zone and warning signs shall be ensured around the workplaces to eliminate
unauthorized personnel/equipment movements.
n) Make sure before installing equipment, that the visual dimensional & quantitative checks have been
carried out properly and that the materials fully comply with the approved shop drawings and
specifications.
o) Ensure that all materials received are inspected (by engineer), found acceptable as per approved
material submittal, and are available to carry out the work.
p) Prior to installation works, the study of the shop drawings, Manufacturer installation details &
specifications to be done. The subcontractor shall carry out a survey of the site related to the area of
the installation works. This shall include a dimensional survey, recording the construction of the
building, the detail, and nature of the existing obstruction, and future installations, in order to fully
coordinate the work to be done.
13 .Installation of Fire Protection Equipment
General
A standpipe system is intended to eliminate the need for excessively long runs of hose for manual
firefighting. With a standpipe system installed in a building, the firefighter can connect a hose to a
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permanently installed valve on the standpipe system and with not more than 100 to 200 ft. (35.5 m to
61 m) of hose, can fight a fire anywhere on a given floor.
According to NFPA 14 ( 3.3.17). Standpipe systems are divided into classes to identify their specific
function. Those classifications are as follows:
Class I. Intended for fire department use only. This type of system is equipped with a 2 ½” (65 mm)
angle valve for hose attachment. The system is not provided with a hose; the fire department will use
its own hose.
Class II. Previously intended for building occupant use only. NFPA 14, Standard for the Installation of
Standpipe and Hose Systems, now restricts this type of system for use by trained industrial fire
brigades.
The Class II system is usually equipped with a 1 ½” (40 mm) hose in varying lengths of 50 to 150 ft (50
m to 45. 7 m) and is designed to discharge water at a rate of 50 GPM (189 Lim) per hose rack at a
pressure of 65 psi (4.5 bar).
Class III. A combination of Class I and Class II. This type of system is usually equipped with a 2 1/2″ (65
mm) angle valve for fire department use and a 1 ½” (40 mm) hose rack assembly for industrial fire
brigade use, although a 2½ “. (65 mm) hose valve with a 2½” X 1 ½” (65 mm X 40 mm) reducer and a 1
½ ” (40 mm) cap and chain can, by definition in NFPA 14, be used to satisfy the Class Ill standpipe
system requirement. It is important to note that many building codes will require the installation of a
Class Ill standpipe system. Such a requirement can be met without the installation of a hose rack
assembly.
14. Installation of Landing Valve Assembly
a) Prior to starting the installation it shall be ensured that the wall has been painted & released to
proceed with the installation.
b) The position of the landing valve shall be readily visible and accessible to the firefighters.
c) After confirming the openings are made shift the required landing valves, cabinets, fire hose reel &
nozzles to the site using adequate manpower.
d) Before installation check for any physical damages on the landing valve, fire hose reel, nozzle &
cabinet.
e) All the Landing valve, fire hose, cabinet, nozzles shall conform to the requirements of NFPA 14,
NFPA 24, and project specifications.
f) Ensure installation height of the landing valve should comply with the requirements (between 1
meter and 1.4 meters)
g) Necessary Piping should be carried out as per the approved drawing.
h) The landing valve shall be placed as per the approved shop drawing.
i) Mount the landing valve cabinet to the opening using approved fasteners.
j) Ensure the cabinet is fixed properly in the opening.
k) Check the doors of the cabinet is opening smoothly.
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I) Ensure the outside of the cabinet is having a “WET RISER OUTLET” indication in 50 mm high red
letters on the inside face of glazing.
m) Fix the landing valve to the completed pipework using necessary tools and equipment.
n) Ensure the landing valve is with a 50 mm diameter inlet & 65 mm diameter instantaneous female
outlet with a blank cap.
o) Ensure the chain valves shall be in a straight or oblique pattern as per the project specifications.
p) Approved pipe nozzle & fire hose having 30 meters long by 65 mm diameter should be placed in
necessary hangers inside the cabinet.
q) Ensure the pipe nozzle & firehouse are placed in a way that they are ready for immediate use.
r) After installation the cabinet should be cleaned as per the approved MAR.
15. Installation of Breeching Inlets
a) Prior to starting the installation it shall be ensured that the wall has been painted & released to
proceed with the installation.
b) Check the approved drawing and mark the portion where the openings should be made for the
recessed type cabinet.
c) The position of the breeching inlet shall be readily visible and accessible to the firefight.
d) Maximum distance between the fire engine hard standing to breeching inlet should be 18 meters.
e) After confirming the openings/markings are made, shift the required breeching inlets & cabinets to
the site.
f) Before installation check for any physical damages on the breeching inlet & cabinet.
g) All the breeching inlets & cabinets shall conform to the requirements of NFPA 14, NFPA 24, &
project specifications.
h) Ensure the centerline of the breeching inlet is 750 mm above the surrounding ground level.
i) Check the 25 mm gunmetal gate valve is fixed properly on the breeching inlet.
j) Fix the cabinet in the opening using approved fasteners, after doing necessary pipe works as per the
approved shop drawings.
k) Fix the breeching inlet to the completed pipework using necessary tools and equipment.
I) Check the 25 mm gunmetal gate valve is fixed properly on the breeching inlet.
m) Ensure the outside of the box is having the necessary indication “WET RISER INLET” in 50 mm high
red letters on the inside face of glazing.
16. Installation of Portable Fire Extinguishers
a) Prior to starting the installation it shall be ensured that the wall has been painted &released to proceed
with the installations.
b) Shift the required portable fire extinguisher to the site using adequate manpower.
c) Before installation checks any physical damages on the Fire extinguisher.
d) Prior to starting the installation it shall be ensured that the shop drawings including coordination
drawings of the respective area are approved.
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e) Ensure the Fire extinguishers have complied with the BS-5423 standard.
f) All the portable fire extinguishers shall conform to the requirements of NFPA 10, & project
specifications.
g) Check the approved drawing for the exact location of each type of fire extinguisher.
h) Ensure the type and capacity of the fire extinguisher by cross-checking it with the approved drawing.
i) Check on the approved drawing for the elevation of the extinguisher from the finished drawing.
j) Mark on the wall the location of approved wall hangers and or wall bracket from the finished floor.
k) Ensure the height of the hanger location does not exceed 1.5 meters.
I) Drill and fix the hangers and support using necessary tools.
m) Check the portable extinguisher is pressurized correctly before installing it on the hanger.
n) Installed Fire extinguisher location to be marked in a drawing and shall be kept in the respective level
escape route plan.
17. Installation of Fire Blankets
a) Prior to starting the installation it shall be ensured that the wall has been painted & released to
proceed with the installation.
b) Before installation checks any physical damages on the fire blanket.
c) Prior to starting the installation it shall be ensured that the shop drawings including coordination
drawings of the respective area are approved.
d. All the fire blankets shall conform to the requirements to the NFPA, & project specifications.
e) Check the approved drawing for the exact location of each type of fire extinguisher.
f) Mark on the wall the location of approved wall hangers and or wall bracket from the finished floor.
g) Drill and fix the hangers and support using necessary tools.
h) Fix the fire blanket on the hanger.
i) Ensure the fire blanket are placed in the region which is easily accessible and the labels are facing
incorrect manner.
18. Installation of Fire Hose Cabinets
18.1 Surface Mounted Fire Hose Cabinets
a) Prior to starting the installation it shall be ensured that the wall has been painted & released to
proceed with the installation
b) Shift the required Fire hose cabinets to the site.
c) Before installation checks any physical damages on the fire hose reel cabinets.
d) All the fire hose cabinets, hose reel, portable fire extinguisher shall conform to the requirements of
NFPA 14, NFPA 1961, NFPA 1963,& project specifications.
e) The location of the fire hose cabinet shall be marked as per the approved shop drawings.
f) The location of the fire hose cabinet should not be disturbed by any obstacles.
g) Using approved anchor & bolt fasten the backbox of the cabinet to the wall.
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h) Ensure the doors will open 180 deg without blocking any valves.
i) Ensure necessary labeling & identification are given to the cabinet.
j) The Hose reel shall be installed inside the fire cabinet utilizing the existing brackets in the cabinet.
The hose reel shall open fully & easily in all directions by just pulling the hose nozzle without even
touching the reel.
k) The piping connection to the hose rack landing valve shall be as per the approved drawing.
I) Ensure necessary pressure reducing valve is installed as per the NFPA 14 (5.8).
m) Ensure the pipe penetration is properly sealed.
n) The Hose reel shall be installed inside the fire cabinet utilizing the existing brackets in the cabinet.
The hose reel shall open fully & easily in all directions.
o) Hose reels with semi-rigid hose shall generally comply with BS EN 671-1.
p) Ensure the maximum length of the hose is 30 meters.
q) Check necessary indication for shut and jet is given in the nozzle as per the approved MAR.
r) Piping connection to the hose reels shall be as per the approved drawing.
s) Hose and fire extinguisher shall be placed inside the fire hose cabinets as per approved shop
drawings & material submittal.
t) Check cabinets shall have suitable ventilation openings.
u) On completion of fire hose cabinet installation, clean interior & exterior surfaces as recommended
by the manufacturer.
18.2 Recessed fire Hose Cabinets
a) Prior to starting the installation it shall be ensured that the wall has been painted &. released to
proceed with the installation.
b) Check the approved drawing and mark the portion where the openings should be made.
c) After confirming the openings are made shift the required fire hose cabinets to the site.
d) Before installation checks any physical damages on the fire hose reel cabinets.
e) All the fire hose cabinets, hose reel, portable fire extinguisher shall conform to the requirements of
NFPA 14, NFPA 1961, NFPA 1963, & project specifications.
f) The location of the fire hose cabinet should not be disturbed by any obstacles.
g) The fire cabinet shall be then placed in the opening with the outer flange flush with the wall and
shall be fitted to the block wall using approved fasteners.
h) Ensure the doors will open 180 deg without blocking any valves.
i) Ensure necessary labeling & identification are given to the cabinet.
j) The hose reel shall be installed inside the fire cabinet utilizing the existing brackets in the cabinet.
The hose reel shall open fully & easily in all directions by just pulling the hose nozzle without even
touching the reel.
k) The piping connection to the hose rack landing valve shall be as per the approved drawing.
I) Ensure necessary pressure reducing valve is installed As per the NFPA 14 (5.8).
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m) Ensure the pipe penetration is properly sealed.
n) The hose reel shall be installed inside the fire cabinet utilizing the existing brackets in the cabinet.
Hose reel shall open fully & easily in all directions.
o) Hose reels with semi-rigid hose shall generally comply with BS EN 671-1.
p) Ensure the maximum length of the hose is 30 meters.
q) Check necessary indication for shut and jet is given in the nozzle as per the approved MAR.
r) Piping connection to the hose reels shall be as per the approved drawing.
s) An extra hose & two approved fire extinguishers shall be placed inside the fire hose cabinets as per
approved shop drawings & material submittal.
t) Ensure cabinets is having suitable ventilation openings.
u) On completion of fire hose cabinet installation, clean interior & exterior surfaces as recommended
by the manufacturer.
19. Competence and Compliance
The Method Statement for Fire Protection Equipment Installations provided shall include a detailed
clause-wise compliance statement in respect of:
Regulatory Compliance
This method statement has been developed to follow the regulatory requirements and as per project
specifications.
Competency of Author/Originator
This method statement includes a statement verifying the competence of the document author/
originator and demonstrating competency.
Construction/Installation (SADD’s)
The project specifications compliance requirements section reference documents SADD’s are deemed
to be a condition of this Method Statement are provided to demonstrate that the procedures
identified are actually adhered to at the site.
Risk Assessment, Health and Safety Compliance
This method statement has been developed specifically for the works specified in the designated area.
A Risk Assessment of this work has been undertaken by the approved safety manager as per
requirement.
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METHOD STATEMENT FOR
HVAC DUCT AND
ACCESSORIES INSTALLATIONS
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SR. EFFECTIVE REV. MSS MANAGER MSS PROJECT CLIENT
CLIENT QA/QC
NO. DATE NO. QA/QC MANAGER SUPERVISOR
HVAC DUCT AND ACCESSORIES INSTALLATIONS
PURPOSE
This method statement of HVAC (Heating, Ventilation, and Air Conditioning) system installation details
the various procedures for installation of HVAC ducts and accessories, return and exhaust ducts,
balancing dampers, fire dampers, and access doors. The purpose of the installation method statement
is to define the implementation in conjunction with relevant ITP, health, safety & environment (HSE)
requirements outlining the responsibility and quality verification of work.
1. Scope of Work
2. Pre-installation
All workers shall attend safety induction training conducted by the contractor and given specific
training on the safe installation method used.
Ensure that the material to be used is inspected and approved.
Ensure that all accessories installation is as per SMACNA Standard (Sheet Metal and Air Conditioning
Contractors’ National Association). Accepted engineering practice and data, such as that found in the
four ASHRAE handbooks and the SMACNA HVAC duct system design manual, should be used to design
systems. (However, SMACNA does encourage the development and use of new technology and it
invites authorities to consider alternative construction methods.)
Ensure that approved materials required to carry out work will be available. All working areas where
possible will require signage and barriers.
Prior to the commencement of work, areas and access will be inspected to confirm that the site is
ready and is safe to commence the work.
All relevant documentation and material applicable to a particular section of works will be checked by
the Site Engineer / Supervisor before the commencement of work. All documentation shall have a copy
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fixed on the project (Material inspection, etc.). For fire-rated air conditioning ducting: all duct work
shall come with documents describing the product’s fire rating. Each duct system must be built to
meet the duct pressure classifications specified on the contract drawings.
Ensure proper storing/handling of the ducts without damaging the surface. All ducts will require open
ends to be sealed prior to delivery. Exterior duct sealant treatment should consist of applying products
marketed specifically as forming a positive airtight and watertight seal, bonding well to the metal
involved, remaining watertight with metal movement, and having a service temperature range of -30°f
(-34°c) to 175°f (79°c).
Check all the duct work are pre-fabricated with tag number labeled and received at the site in
accordance with specifications and correct dimensions as per approved drawings,
The Site Engineer / Supervisor will give the necessary instructions to the tradesmen and provide
necessary approved construction / approved shop drawings to avoid wrong connections during
assembly or installation.
The Site Engineer / Supervisor will also check that the tools and equipment available are in compliance
to contract requirements. Check all tests are being carried out where required Portable Appliance
Testing (PAT) before being used to ensure they are fit.
3. General Requirements
This method statement of HVAC covers the installation of HVAC duct and accessories at the site. The
majority of the duct shall be pre-fabricated off-site either by the contractor or from an outsourcing
company. Fabrication on site shall be minimal but a fabrication workshop shall be on site.
Pre-qualification documents for such facilities used for duct fabrication will be submitted to the
Consultant for approval. All the relevant information (e.g. Location of the fabrication shop, production
capacity, type of machinery, quality systems, the method used for communication, transportation of
materials, etc. will be included in the pre-qualification document.
Approved and coordinated ducting shop drawings will be provided to the fabrication workshop for
tagging, and the tagging list will be reviewed subsequently by the construction engineer.
Each section, such as ahu, outdoor air (oa), supply air (sa), return air (ra), and exhaust air (ea), should
be clearly labeled with arrows indicating the proper flow directions.
Delivery of fabricated ducts to the site will be coordinated with the construction program to avoid
storing ducts at site stores for long periods. Duct delivered shall have the openings covered by
polyethylene at all times until site installation to prevent dust accumulating in the inside surface.
A copy of this approved construction installation method statement of HVAC along with the relevant
specification sheets from the contract document will be forwarded to the fabrication workshop to
ensure the quality of duct work fabrication meets the contract requirements.
Proper lifting machine to be use and operator is well trained & knowledge of procedural installation for
all duct load to be loaded on the lifting machine.
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Train the owner’s/client’s maintenance staff for operation and preventative maintenance as per
project specifications.
4. Installation-
4.A Installation of Duct Horizontal Run
Scaffolding shall be assembled by competent personnel according to the height where installation shall
take place. All safety requirements shall be met as per the requirements in the Risk Assessment
prepared by HSE Department.
Mark the route of duct on the soffit of the slabs and non fire rated walls. Ensure that slabs and non fire
rated walls and floors are free from damage and ingress of moisture.
Determine the position of support as per approved construction drawing, coordinate layouts, and
specification and fix the supports using anchor bolts and ensure that all fixings (threaded rods, angles,
clamps, etc.) are straight and secure. Any cut edges of angles, channels or threaded rods will be
painted with touch-up with zinc-rich paint. Adequate supports to be provided before and after fittings,
bends, offsets, etc.
Prepare and fix the duct supports as per the approved construction drawing and specifications. Using
either self-drilling anchors or an appropriate size masonry drill, carry out the preparatory works in the
slab to receive the anchors. Consider anchor manufacturer’s recommendations for diameter and depth
of the hole.
Fix the anchors and ensure that they are adequately supported on either side. Hang the threaded rod
and use lock nuts and washers to lock it with the slab. Remove the sharp corners at the open end of
the GI threaded rod and angles. Fix the angle with a lock nut and a nut below. Load test shall be carried
out prior to fixing.
Use only undamaged rust free bolts nuts and washers in joining flanges together and tightening bolts.
Transport the duct pieces and fittings to the final location. Pre-assemble, (where ever possible) the
duct pieces and fittings as per approved shop drawing ensuring the horizontal and vertical alignment.
For large-size ducts, it shall be delivered to the site in section and assemble on site. A manual duct
lifter, trolley, or movable pallet shall be utilized in the transporting and lifting of ducts whenever
space/location permits. If not possible, duct pieces shall be transported manually. Lifting of duct
materials to the rooftop shall be done using a tower crane. All necessary permits shall be issued before
the execution of any works.
All known branches and tapping for collar/flexible etc. may be done during the assembly stage.
Lifting of the duct onto the supports ensuring that each length is aligned and leveled with the
preceding length as per dimensions shown on approved shop drawings. Ensure that all supports are
properly loaded adequately padded with load-bearing material.
Approved duct sealant shall be applied to the joints. Any excess sealant shall be removed so that the
joint is left in a clean and tidy condition. Use only undamaged bolts nuts and washers to join mating
flanges together and tighten bolts.
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Ensure that duct work is clean and no construction debris exists within duct work before proceeding to
the next length. Permit required for the sealant. COSHH assessment to be carried out.
All open ends of the cleaned duct works shall be temporarily closed with polythene sheets before
leaving the job site to prevent ingress of moisture and dirt.
Ensure that all accessories such as silencers, volume control dampers, balancing dampers, fire
dampers, access doors, test points, sensors, and associated plant equipment are installed in
accordance with approved shop drawings. Make certain that the installed units are free from damages.
Install sound attenuation equipment and suitable materials according to approved shop drawings and
HVAC installation method statement.
Installation of duct complete with accessories shall be checked & inspected before applying thermal
insulation sheets at duct work joints.
Ducts that are interrupted at the curb should be flashed to divert water over the curb or overhang the
top of the curb.
Locate ductwork runs, unless otherwise indicated in the detailed shop drawings through horizontal
and vertical checking, and avoid diagonal runs wherever possible.
If AC duct is greater than 1.2 m in length, then ensure to support a separate bracket under the
connected duct and from it, a hanger-wire can be suspended for ceiling installation.
All high-level cutting, etc should be kept to a minimum.
Ductworks penetrating through external walls and floors shall be sealed to the wall.
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4.B Installation of Vertical Risers
The procedures are similar to the horizontal ducts. The following points have to be taken care of in
duct riser installation:
Install duct support on the shaft as per the latest approved shop drawings.
Duct pieces shaft be pre-assembled / insulated before taking to final location depending on the
available space. If not possible to distribute duct pieces in floors, transport duct pieces to the roof or
topmost portion of the building using available lifting equipment (tower crane as per coordination
utilized in the transporting and lifting of duct whenever space/location permits. If not possible, duct
pieces shall be transported manually. Lifting of duct materials to the rooftop shall be done using a
tower crane. All necessary permits shall be issued before the commencement of any works.
All known branches and tapping for collar/flexible etc. may be cut during the assembly stage.
Lifting of the HVAC duct onto the supports ensuring that each length is aligned and leveled with the
preceding length as per dimensions shown on approved shop drawings.
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Ensure that all supports are properly loaded & adequately padded with load-bearing material.
Approved duct sealant shall be applied to the connected joints. Any excess sealant shall be removed so
that the joint is left in a clean and tidy condition.
Ensure that duct work is clean and no tools/ construction debris exists within duct work before
proceeding to the next length. COSHH assessment to be carried out.
All open ends of the ductworks shall be temporarily closed with polythene sheets before leaving the
job site to prevent ingress of moisture.
Ensure that all accessories such as silencers, volume control dampers, balancing dampers, fire
dampers, access doors, test points, sensors are installed in accordance with approved shop drawings.
Install sound attenuation equipment and suitable materials according to approved shop drawings.
Installation of duct work complete with accessories shall be checked & inspected before applying
thermal insulation at duct work joints.
All high-level cutting, etc. should be kept to a minimum.
4.C Installations of Grilles and Diffusers
Check the location of grilles and/or diffusers if properly coordinated with light fixtures as per the
approved reflected ceiling plan.
If grilles or diffusers are for unducted return air, ensure that the wooden/steel frame is in place
provided by others. Make sure that the frame is properly supported and not sagging. Check ceiling
level when installing the grilles or diffusers.
Fix the grilles collar securely to the wooden/steel frame with screws and seal the gaps with sealant.
Install the removable face to the assembly.
If grilles or diffusers are for a ducted system, make sure that plenum box or duct drops are in the
correct location as per the approved shop drawings and elevation as per ceiling requirements.
Fix the grilles collar securely to the plenum box or duct drop by metal crews and seal the gaps with
sealant. Install the removable face to the assembly.
For a linear diffuser, fix it to the plenum box as per the manufacturer’s instruction and
recommendation. As an additional precaution, metal screws can be used to fix the linear diffuser with
the plenum box.
Proper care must be taken while installing grilles and/or diffusers to avoid surrounding painted
surfaces are not damaged.
Take note that dampers inside grilles or diffusers should be used only for fine adjustment during air
balancing. Major adjustments should be done with a volume control damper in the duct branch. This is
to avoid high sound levels.
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5. Ductwork Insulation and Jacketing
5.A Insulation Requirements
Indoor ducts are to be insulated with 25mm thick fiberglass insulation. Outside air ducts will be
insulated with 50 mm thick insulation material as per project specifications.
Kitchen hood exhaust ducts are to be insulated with 2hr fire rating fiberglass as per project
specifications.
Exposed ducts will be insulated with 50 mm thick and 48-kg/ cubic meter nominal density fiberglass
board as per project specification.
5.B Insulation Procedure
Installation of ductwork (complete with accessories) shall be checked and inspected before applying
insulation at joints.
Ensure that all edge joints are closely butted, ends are flush, and seated properly.
Clean the surface of the duct to remove dust and grease.
Spread duct adhesive at the rate of 4.5 sq.m/liter.
For large ducts fix stuck-up pins at regular intervals. Apply duct adhesive on duct (at the rate of 4.5
sq .m/liter) and fix insulation firmly in position. Insert stoppers over the pins to hold insulation firmly
to the duct. Bend the pin to lock the stopper in position and seal. The insulation in the bottom portion
of the ducts should be kept under pressure by some means till it gets dry and sticks firmly to the duct.
Install the ducts as per the approved shop drawings.
Cut pieces of insulation to suit the width of joints between ducts, spread duct adhesive on duct joints,
and stick insulation firmly in place. Seal the joints with aluminum foil tape.
When insulating VCD’s & splitter dampers, ensure that the handle is not covered by the insulation to
permit the opening and closing of dampers. Ensure access doors are not covered fully and are easy to
open/close.
Where insulated ductwork passes through fire-rated walls/partitions the gap between sleeve and
ductwork shall be filled with an approved fire barrier material.
5.C Aluminum Jacketing
Obtain necessary clearances from the engineer for insulation work (both the workmanship and quality)
before proceeding with the jacketing application.
Check the materials for damage/defects before starting the fabrication works.
Take a necessary measurement for jacketing.
Develop the appropriate cutting plan of the metal sheet giving allowances for cross-sectional and
longitudinal overlaps.
Cut the sheet along with the marking.
Aluminum sheet required cross bend and perform grooving.
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Fabricated sheets are fixed to the insulated surface with a minimum of 50mm lapping on all on all
seems and secured with pop rivets and SS screw.
Fill the joints with vapor retardant mastic or sealant.
6. Materials
Approved material submittal for installation method statement of HVAC:
HVAC Duct
Duct Hanger and Supports
Accessories
Fire Dampers
Motorized Damper (Fire Smoke)
Volume Damper
Zone Control Damper
Variable Air Volume (VAV) materials
Air Terminal Devices
Thermal Insulation
Fiberglass Duct Insulation
Aluminum sheet for Jacketing
Adhesive
Aluminum tape
7. Tools and Equipment
Hand tools
Rivet Gun
Wooden Mallet
Insulation cutting knife
Spirit level
Level threads
Step Ladder
Scaffoldings
Sheet metal cutting tools and bender
Adjustable spanners
Riveter
Drill machines
Hammers
Grinding machine
Angle cutters
Adhesive applicator
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8. Health, Safety and Environment
All employees shall undergo safety induction from the safety department. The task supervisor shall
ensure that all men under him have undergone the induction.
All employees assigned for this task shall wear safety shoes, helmets, goggles, and hand gloves as a
minimum requirement.
Necessary hazard control arising from this activity shall be briefed by the immediate supervisor to all
the operatives.
The task supervisor shall inspect the area for any potential risk before commencing the activity. The
area safety officer shall ensure that the risk control in the risk assessment is addressed and
implemented.
Check that tools and equipment available are in compliance with the contract requirements and
project specifications.
Storage, handling, and use of chemicals shall be as per the MSDS specification. Only a minimum
quantity of chemicals shall be kept on the site storage area with all control measures put in place.
Insulation like fiberglass cool shall be in a minimum quantity container undercover. A safe and
protective storage area will be provided on the site.
Operatives will collect the adhesives and paints from the chemical stores in an appropriate metal
container with a hazard label. The chemical container shall be returned to the store after use or at the
end of its shift.
Daily housekeeping and waste disposal shall be done at the end of each shift.
Erection of scaffolds and inspection of scaffolds shall be carried out by third-party trained operatives.
All power tools shall be 110 V rated. Use of higher power tools other than 110 V will be subject to
dispensation.
9. Inspection for Method Statement of HVAC Installation
Inspection request shall be raised promptly for the Consultant in accordance with the approved
Inspection and Test Plan (ITP) related to the installation Method Statement of HVAC.
The inspection shall be recorded in the approved checklist attached to the approved ITP.
Records:
QC Inspection checklist report as per approved ITP for installation Method Statement of HVAC.
Inspection request duly signed-off by Consultant. Moreover, verify that all mechanical and electrical
inspection has been completed as per related ITP.
As-built drawings of the HVAC duct, fittings, and accessories from the final construction.
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METHOD STATEMENT FOR
INSTALLATION OF CABLE TRAYS
SR. EFFECTIVE REV. MSS MANAGER MSS PROJECT CLIENT
CLIENT QA/QC
NO. DATE NO. QA/QC MANAGER SUPERVISOR
INSTALLATION OF CABLE TRAYS
1. PURPOSE
This Method Statement formalizes the requirements for the Installation of Cable Trays, Ladders, and
Trunking System. The specifications, procedures, and guidelines contained in this Method Statement
specify the technical requirements to be followed and also act as a reference to clearly establish
defined standards for work assessment. Moreover, this document shall provide guidelines to check
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that specified materials are installed and agreed procedures are implemented during the execution of
work and to define the responsibilities for controlling the execution.
2. SCOPE
The scope of this Method Statement is to describe the sequence of activities involved in Installation of
Cable Trays, Ladders and Trunking System as per the requirements of contract specifications, and
codes, standards of the project titled as under: “Name of the Project Here”
3. SYSTEM DESCRIPTION
For an effective Cable Management at the project site, cable Ladders, cable trays, and trunking
systems are applicable to meet the load requirements. These shall be used for all types HV/LV/MV/ELV
cables containment includes but not limited to main cables routed to branch cables for main circuits,
LV cabling inside Tunnel, Cables routed to carpark, buildings, substations, control, and power cables,
fire detection and alarm system, 415V switchgear, switchgear and control gear, panels, all distribution
boards, public address system, etc.
4. DEFINITIONS
Client – xxxxxx
Project Management-Construction Management (PM-CM) – xxxx
Construction Supervision Consultant (CSC) – xxxxx
Main Contractor – xxxx
Supplier/Vendor – Seller of material as defined in the project specification
Must – Signifies a legal or statutory requirement
Shall – Signifies a requirement made mandatory by this specification
May – Signifies a feature, which is discretionary in the context in which it is applied.
Will – Signifies feature which the supplier may assume to be already present
5. REFERENCES
Project Electrical Specification
BS EN 61537 Cable tray system and cable ladder system for cable management
Approved material submittals
Approved shop drawings
6. ABBREVIATIONS
HSE Health Safety and Environment
QA/QC Quality Assurance and Quality Control
MST Method Statement
RSK Risk Assessment
ITP Inspection and Test Plan
PQP Project Quality Plan
INR Inspection Request
PPE Personnel Protective Equipment
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 458 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
MEP Mechanical, Electrical & Plumbing
STARRT Safety Task Analysis Risk Reduction Talk
7. RESPONSIBILITIES
A. General
1. Project Manager (MEP) will be responsible to manage, execute, complete, and handover the
construction activities within approved budgets and resources in compliance with Project
Requirements as specified in Project Specifications. He will be overall in charge of implementing
Method Statement in accordance with QA/QC and HSE requirements.
2. Construction Manager will be responsible for managing construction activities and will lead and
communicate site Supervision, Subcontractors and Vendors to assist them in working to the Project
Schedule by conforming QA/QC and HSE requirements at the site.
3.HSE Manager will be responsible for plan, coordinate, and implement issues and directives within the
organization. He ensures safe environmental working conditions for all employees.
4.QA/QC Manager will be responsible for supporting the project team in implementing and
maintaining Quality Management System for the project through PQP, ITP, MST, and Procedures in
compliance with Project specifications, Codes, and Standards.
5.HSE Officer will ensure enforcement of safety procedures in accordance with the approved HSE Plan.
Will be closely monitoring the site engineer’s strict implementation of the MS and Risk Assessment,
the use of proper tools and equipment to maintain safety, certifications of equipment and their
adherence to safety regulations, reporting of any unsafe work, or stopping work that does not comply
with HSE procedures.
6. Site Engineer will be responsible for carrying out all construction-related activities with compliance
to HSE and QAQC requirements as per contract specifications, drawings /documents, codes, and
standards.
7.QA/QC Engineer will be responsible for conducting inspections as per PQP.
8.Supervisor/Foreman will be responsible for coordinating all works and workers related to the job.
9. Electrician / other tradesmen will be responsible for assisting his superiors during all construction
work-related activities following HSE and QAQC requirements.
10. Store In-charge receives and inspects all incoming materials and reconciles with documents;
processes and distributes documentation; reports, documents, and tracks damages and discrepancies.
11. The security guards will be clearly visible, vigilant, respond quickly and correctly during the crisis,
observing and reporting, checking and monitoring, maintain order among workers, and offer safety
warnings and tips.
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B. Organization Chart
C. Interfacing with other Operations
Other Mechanical, Electrical and Plumbing works and Architectural, Civil and Structural Requirements
D. Duration, Phasing with the Subcontractors
All works associated with Construction work referred to in this Method Statement shall be completed
as per the project schedule.
E. List of Subcontractors
Main Contractor: xxxxxx
Subcontractors for MEP: xxxxxx
F. Handling and Storage
F.1 Workmanship
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1. All plant and equipment shall be stored off the ground under weatherproof cover ready for
incorporation in the works. All electrical apparatus shall be examined and cleaned before installation.
All open conduit ends shall be fitted with plastic caps or suitable protective covering to prevent the
ingress of foreign matter. All drums with cables shall be protected from direct sunlight.
2. The lay down area shall be arranged for offload the materials prior to transport at the site.
3. The storage area shall be cleaned and is at a minimum height of 1 ft from the ground level. The
materials shall be stored in a shaded area to protect it from exposure of direct sunlight/rain etc.
Separate areas in the storage zone must be marked for different materials.
4. Slings used to lift the materials must be checked for damages and defects. Slings shall not be
shortened with knots and bolts or other makeshift devices. Slings should not be kinked and should not
be loaded in excess of their safe working load. Slings shall be padded or protected from the sharp
edges of their load.
5. All employees shall be kept clear of load about to be lifted and of the suspended load. Hands and
fingers shall not be placed between the slings and their load while the sling is being tightened around
the load. Slings shall not be pulled from under a load when the load is resting on the sling. Always use
two-point loading to avoid load slipping.
6. Forklift / Crane must be the third party certified and fit for the purpose. Ensure that operator must
be qualified, trained, and with a valid license. Ensure daily inspection of forklifts has carried out prior
to commencement of work.
7. All plant and equipment shall be stored off the ground under weatherproof cover ready for
incorporation in the works. All electrical apparatus shall be examined and cleaned before installation.
All open conduit ends shall be fitted with plastic caps or suitable protective covering to prevent the
ingress of foreign matter. All drums with cables shall be protected from direct sunlight.
F.2 Specific Requirements
The Site Store In-charge/Storekeeper shall ensure the following in particular:
1. Straight lengths of trays, ladders, covers, and channel
It is recommended that where possible non-metallic banding is used in order to avoid rust stains
forming on galvanized products and contamination of stainless steel products. Where products of five-
meter length or above are packed in bundles, they shall be supported with a sufficient number of
timber bearers which provide sufficient clearance to accommodate the forks of a forklift. Bundles
should be placed on a flat level surface with timber bearers. If the bundles are stacked on top of one
another they should be aligned vertically.
2. Boxed and bagged parts
Boxes and bags should be stacked onto suitably sized pallets for handling by a forklift. Pallets of parts
must be kept dry and stacking should be avoided.
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3. Tray and Ladder Fittings
Small parts should be stacked onto suitable sized pallets for handling by a forklift. Each pallet should
be suitably wrapped in order to secure the parts. Pallets of parts must be kept dry and stacking should
be avoided. Large parts should be packed and transported in the same way as straight lengths detailed
above.
4. Storage
Products that are either Hot dipped Galvanized after manufacture, stainless steel, or nonmetallic can
be stored outside without cover (excluding boxed items). When stored outside products should be
stacked in a method that ensures adequate drainage. However outside storage is not recommended
for galvanized products due to ‘wet storage stain’ galvanized products if exposed to become wet while
stacking awaiting transportation/installation, the finish may quickly suffer from unsightly staining and
powder on the surface. This is known as ‘wet storage stain’.
Ideally, the metallic products should be stored undercover in a dry, unheated environment and be
loosely stacked off the ground to ensure adequate ventilation. All products should be stored away
from areas where processes or activities could cause damage or contamination.
F.3 Responsibilities
1. The Store In-charge shall ensure that all approved supplies be delivered to the site as per the
approved material submittal with the manufacturer’s seals, labels, or other proof of origin intact.
These labels and seals shall not be removed until the material is required for use and shall be retained
for inspection by the Consultant and QAQC.
2. Each material item shall be allotted a distinct and separate reference number and mentioned on
material requisition. Make sure that material is approved/examined by the Consultant and QAQC and
associated documents/test certificates are approved.
3. The Site Engineer shall be responsible for the off-loading and handling of the materials on-site and
shall ensure that materials delivered to the site are properly protected against mechanical damage.
8. RESOURCES
A. Tools and Equipment
The following type of equipment and tools shall be utilized for the installation:
a. Wire cutters
b. Hacksaw
c. Measuring tape
d. Drill machine
e. Wooden hammer
f. Flat file
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g. Screwdrivers
h. Open and box spanners
i. Base Cutter
j. Drill with Bits
k. Spanners
l. Torque Wrench
m. Set Square
n. Socket wrench and sockets
o. Cranes
p. Forklift
Note:
All testing equipment and measuring tools to be used shall have a valid calibration certificate prior to
usage.
All lifting equipment and machines shall be 3rd party certified with valid certificates.
B. Materials
a. The material shall be used after being approved by Approved Material Submittals.
All material to be used shall conform to the project specification.
C. Site Preparation and Planning
C.1 Preparation
The main Contractor shall ensure that all gate passes, permits, tools, materials for safety precautions,
manpower, and equipment are available before commencement of work.
The Site Team shall make sure that access roads are always clear from any obstruction and site is
always accessible.
C.2 Site clearance
Before commencing the work, the area shall be cleared of all debris, materials, or other obstructions.
C.3 Traffic Management
The Site Team with the assistance of the Safety Officers shall coordinate logistics and materials
movement through site following the direction and road signs displayed on site. The required diversion
routes shall be marked on drawings including the required traffic signs.
The Work Permits and Operator Certificates shall be compiled and files for reference by authorized
personnel. Temporary traffic signs, barriers, and flagmen will be deployed to control traffic flow in
accordance with and Traffic Management of the HSE Plan. At the end of each ramp, there will be a
transition area to give the driver the opportunity to watch the access roads before joining thereto.
C.4 Pre-construction Safety Meetings:
The meeting shall be scheduled prior to the beginning of the work and before any Sub-contractor
starts on the project. Safety awareness meetings will be conducted every working day morning/every
other day to brief the workforce in safety prevention measures. The equipment check for safety shall
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be recorded/ documented during the daily Safety Awareness Meeting. Traffic safety will be discussed
to emphasize these meetings. Each worker will be instructed to follow specific safety requirements
related to his trade. They will be required to follow installed safety signs, observe barricades, and use
PPEs.
Main Contractor Safety will perform hazard risk analysis by identifying all steps, hazards identified in
those steps, with a focus on the relationship between the work task, the tools, and the work
environment. After identifying uncontrolled hazards; Main Contractor will take steps to eliminate or
reduce them to an acceptable risk level.
General Contractual Safety, Health, and Environmental requirements.
Roles of the contractor, subcontractors, authorized representatives, and all project workers.
Accident reporting requirements.
Specific details of the work to be performed along with the use of personal protective equipment.
Emergency procedure.
C.5 Operating Procedures:
A site investigation has to be carried out to develop safety precautions and measures prior to the
commencement of the work. After such investigation, relevant signboards will be displayed and
barricades will be installed where and as necessary, such as but not limited to the following:
Relevant information, advanced signs, warning, and mandatory signs will be placed as required.
Radio Communication system would be used where normal communication is impossible. After
completion of the work, safety cones and barricades have to be removed accordingly.
9. PROCEDURE
A. Pre-Installation
a. All relevant documentation approved shop drawings, and material applicable to a particular section
of works will be checked by Site Engineer prior to commencement of work.
b. Ensure that Material received is in compliance with the project specifications and is approved.
c. Ensure that all required materials and accessories are delivered, inspected, and approved by the
Consultant and are readily available at the site to carry out the work and coordinated with related to
Civil contractor.
d. Prior to the commencement of work, areas and access will be inspected to confirm that site is ready
to commence the work.
e. All relevant documentation (includes MST and RA are approved, obtain necessary work permits, fill
up STARRT cards after completion of daily toolbox talk), approved shop drawings and material
applicable to a particular section of works will be checked by Site Engineer prior to commencement of
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work.
f. The Site Engineer/Site Supervisor will give necessary instructions to tradesmen (Electrical) and
provide necessary approved construction/shop drawings.
g. The Site Engineer/Site Foreman will check that proper tools and equipment are available to carry
out the work and are in compliance with contract specifications.
h. The Site Engineer will explain his team about HSE precautions to be observed.
i. The Site Engineer/Foreman ensures the cleanliness of the area.
B. Installation
The cables shall be routed on the cable ladder and tray as far as is practicable. Cable containment
system includes ducts, trays, supports, trunking system, ladder, road crossing ducts, and associated
fittings/supports. In a particular installation of Cable trays/ladders and cable trunking systems are
discussed below.
B.1 Installation of Cable Trays/ Ladders
1. Cable Ladders, cable trays, and their supports should be strong enough to meet the load
requirements of the cable management system including cables and any future cable additions any
other additional loads applied to the system.
2. Fish plates or approved jointing materials as applicable (as per approved drawings and project
specifications) to be used at tray joints for tray size 400 mm and above.
3. Types and sizes of cable tray and ladder supports shall be as per approved shop drawings and
project specifications.
4. Cable Ladder is suitable for a power cable for HV/MV/LV large cables, made up of rungs with a rigid
profile. However, Cable Tray is made of bent sheet, with perforation on base or side; suitable for
power cable and instrument/data cables.
5. When considering the installation of the cable support system it is imperative to avoid the cutting or
drilling of the structural building members without the approval of the team leader.
6. Cables installed on ladder racking shall be spaced by one clear cable diameter of the largest cable.
7. Any installed cable ladder, cable tray can be considered structurally as a loaded beam when installed
horizontally. However, any vertically oriented component, whether cable ladder, tray or support act
structurally as a column. While installation the structural consideration of beams and columns must be
considered in terms of load management of cables.
8. All beams deflect when a load is imposed. The magnitude of the deflection depends upon a load of
the beam, load type, span, size of the beam, the material of the beam, and how the beam is fixed and
supported. Particular attention is given while installation by considering the above.
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9. Where cable ladder and cable tray support systems are fixed to primary supports e.g. structural
steelwork or elements of the building, it is important to ensure that the primary supports are strong
enough to carry the imposed loads.
10. The fixings used to connect the cable ladder/tray support systems to the primary supports also
need to be checked to ensure that they are strong enough.
11. When several levels of cable ladder or cable tray are mounted on the same threaded rod in a
multiple level installation, preferably shall not be the same support for tray and ladder and it shall be
as per approved drawings and project specification. It is important to ensure that the total load on any
pair of rods does not exceed the safe working load of the rods or their attachment points.
12. Cantilever arms horizontal runs of cable ladder or cable tray to be mounted to vertical steel,
concrete or masonry surfaces, or to channel support systems.
13. Threaded rod suspension brackets are useful when space is limited.
14. Wall support brackets are an effective way of fixing any width of cable ladder or cable tray, running
either vertically or horizontally, to a vertical support.
15. Overhead hangers enable the tray to support to be supported from a single-threaded rod giving
easy access for laying cables from one side of the tray only.
16. Hold down brackets and clips are used for securing cable ladder and cable tray to horizontal
supports. If allowance for thermal expansion is required then the brackets and clips are generally not
fixed to the cable ladder or cable tray.
17. Cable ladders or cable trays should not be laid down directly onto the roof or floor of an
installation. Cable ladder and cable trays should be mounted far enough off the floor or roof to allow
the cables to exit through the bottom of the cable ladder or cable tray. If a channel support system is
used for this purpose, mount the channel directly to the floor or roof and attached the cable ladder or
cable tray to the channel using the fixings recommended by the manufacturer.
18. The Safe Working Load (SWL) specifies load test methods for determining the SWL’s which can be
supported by the cable ladder and cable tray. There are different types of load tests depending on the
span size, possibly with end reduced span size, and positions of joints.
This is particularly important for installing straight cable ladders and cable tray lengths.
19. After the supports are in place, the installation of a cable ladder or cable tray can begin at any
convenient location. It is not necessary to begin at one end of the run in all cases. It is ideal if
circumstances permit to layout the system so that joints fall in the desired positions as this will visually
aid installation ad also maximize the system rigidity.
20. To begin the installation, place a straight length across two supports so that the ends of the length
are not directly on the support. If the support span is equal to or greater than the length of the straight
lengths then bolt two lengths together for this step.
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21. Place the next straight length across the next support and attach it to the previous length with a
pair of coupler plates and relevant fixings with the bolt heads on the inside of the cable ladder or cable
tray unless otherwise specified by the manufacturer.
22. Manufacturer’s published data should be consulted in order to ascertain the maximum span that a
product can be used with and any special provisions required for long spans. Special provisions are
required especially if used externally where there may be dynamic loadings.
23. Site modifications may be required sometimes during installation. Care must be taken to ensure
that all modifications on site to cable ladder/tray are performed by competent personnel only.
24. Cable ladders or cable trays that have been hot-dip galvanized after manufacture will need to be
repaired after cutting, drilling and de-burring. Repairing a galvanized finish must be done usually a zinc-
rich paint. Other protective coatings that are cut or damaged must be repaired with compatible
coatings.
25. The installation of vertical runs of tray along the line of vertical expansion joints in the structure of
the facility shall not be allowed.
26. Trays shall not be smaller than the minimum size stated on the Drawings or specified later and shall
be so sized; if not specified, then calculate the size of the tray and submit to the Consultant for
approval. The minimum acceptable size for cable tray shall be 50 mm.
27. Use expansion connectors where required.
28. Where specified, install warning signs at 1500 mm centers along with cable ladder/ tray.
Erection
1. Cable trays arranged one above the other shall have spacing in relation to their width not exceeding
a ratio of 1:2 with a minimum distance of 150 mm. Install fixings and supports as
(a) at 2 meter centers or as specified in project documentation
(b) 150 mm from bends, tees, intersections, and risers
(c) as close as practicable to joints
(d) each side of expansion joints.
2. Supports shall be selected from the types, to suit the site conditions. These may be GI Channel or
brackets, wall support brackets, cantilever beams or steel channels.
3. Avoid mid-span joints.
4. All calculations relating to tray work and tray support demonstrating acceptable mechanical stresses
and sag should be considered.
5. Flexible expansion coupler can be used to provide a semi-flexible joint where straight cable ladder or
cable tray runs span separate structures between which some relative movement is possible.
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6. Horizontal and Vertical adjustable couplers may be used for fabricating fittings on-site from cut
lengths of the cable ladder.
7. Fittings facilitate a change of direction or width and provide intersections between straight cable
ladder or cable tray runs. Flat bend, inside or outside riser, equal or unequal tee, 4-way crossover, or
reducer are examples. These may be used depending upon requirements.
8. The radius of the cable ladder and cable tray fittings is usually determined by the bending radius and
stiffness of the cables installed on the ladder or tray. Typically the cable manufacturer recommends a
minimum bend allowance for each type of cable.
9. The radius of the cable ladder or cable tray fitting should be equal to or larger than the minimum
bending radius of the largest cable installed.
10. Accessories like divider and covers are used for supplementary functions such as cable retention
etc. Dividers are used to physically separate different types or groups of cable
11. within one cable ladder or cable tray run, dividers should be installed prior to the cable being laid
and then fastened using the fixings.
12. Covers provide mechanical and environmental protection for cables being carried by cable ladder
or cable tray, which can be closed or ventilated.
13. Cable trays installed on roofs shall be supported using GI brackets or concrete blocks. Removable
cable tray cover shall be fitted.
14. Access shall be available at all times to remove or replace cables with a minimum of 400 mm
between trays and physical obstructions, A/C ductwork, etc.
15. Fire sealant or other approved materials to be applied wherever passing through fire-rated wall
and riser.
Earthing
1. Cable trays and accessories shall be electrically and mechanically continuous throughout their
length.
2. The entire cable tray system shall be bonded and 12 mm x 2.5 mm tinned copper links shall be
bolted across each joint in the system by means of a bronze nut and bolts, complete with flat and
spring washers.
3. All cable trays shall be provided with earth continuity along the whole route of cable trays which
shall be bonded to the main earthing system of the facility. The earth continuity copper strap shall be
fixed on the cable tray by means of bolts.
4. For Earthing works refer to Approved Method Statement for Earthing.
B.2 Installation of Cable Trunking system
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1. Site Supervisor/foremen will carry out a site Survey and mark the route of cable Trunking per latest
approved drawings.
2. Cable Trunking shall be properly aligned, and securely fixed at maximum 2 meters centers on
straight runs. At bends, angles and offsets fix with additional fixings at centers not exceeding 150 mm
on each side of the fitting.
3. Make a trunking joint where trunking crosses Settlement and Expansion Joints. Make connections
through slotted holes allowing a 10 mm movement horizontally and vertically. Earth continuity link
across joints shall be braided copper tape which is long enough to allow for the maximum movement
of trunking. Fold braid ends.
4. Fire Barriers (non-combustible, non-metallic) shall be installed where specified. Also where trunking
passes through walls, floors, and ceilings and at each floor level when trunking is installed in riser
ducts.
5. Make connections to conduits, multiple boxes, switchgear, switchboards, motor control centers, and
distribution boards with flanged units.
6. Fix Cable Retaining Straps at not exceeding 1m centers.
7. Raceway and Wireway
(a) install products in accordance with manufacturer’s instructions.
(b) use flat-head screws, clips, and straps to fasten raceway channel to surfaces. Mount plumb and
level.
(c) use suitable insulating bushings and inserts at connections to outlets and corner fittings.
(d) provide steel channels for supporting the wireways.
(e) close ends of wireway and unused conduit openings.
(f) earth and bond raceway and wireway
(g) provide circuit cable clamps at no greater than 500 mm intervals for raceways installed in vertical
runs.
Cleaning
a) make good cutting and damages of the steel trunking systems, remove burrs and rough edges and
corrosion and treat with a rust proofing agent, followed by an application of zinc epoxy
(b) provide a coat of paint to match adjacent surface for PVC system
(c) provide the paint after application of the zinc epoxy for steel trunking system.
10. HEALTH SAFETY AND ENVIRONMENT
A. HSE Risk Assessment
Please refer to the attached document in Appendix A.
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METHOD STATEMENTS
TITLE:
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MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
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NAME:
B. Permit and Licensing Requirements
The required permit to work shall be obtained prior to the commencement of work. This shall be
coordinated with HSE.
C. Pre-Start Safety Briefing Arrangements
C.1 Protective and Safety Equipment
All workers Involved shall be equipped with adequate PPE as stated below:
Safety Helmet with Company Logo
Safety Boots
High Visibility Vest
Safety Goggles
Hand Gloves
Coveralls
High voltage gloves (Job Specific)
C.2 Information to Personnel
Safety Induction
Job training
Superintendents Notices/Memos
Toolbox talks
STARRT Card
C.3 Special Safety Requirements:
All necessary personal/protective equipment (PPE) as well as harness be provided.
Rigging Team, wearing distinctive vests, shall be assigned to help operators manoeuver their
equipment.
The equipment operators shall possess the required licenses and certificates.
Generated dust shall be controlled by periodic water spraying.
The required permit to work shall be obtained prior to the commencement of work.
The project safety officer is responsible along with the project zone site engineer for ensuring that all
operations are carried out with due regard to the safety of all project personnel & property.
Working at height to be monitored with due care.
In case of working at night, please refer to Method Statement for Night Works ref.: xxxxxxxx
C.4 Emergency Procedures
(Emergency Site Contact Numbers Here)
11. QUALITY ASSURANCE AND QUALITY CONTROL
A. Quality Assurance Requirements
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The main Contractor shall provide the required documents for the Consultant’s approval prior to
initiating the execution of this activity as per project specification requirements.
The Quality Control requirement shall include related to ITP’s and other related documents as
applicable.
Refer to Inspection Test Plan (See Attachment B)
Applicable codes and standards referenced for materials and installation in MST.
B. Quality Assurance Process
The main Contractor shall notify the Engineer 24 hours in advance prior to start of activity and
Comments from the Site Instruction will be complied with the satisfaction of the consultant.
The main Contractor shall consult the public utility authorities not less than one month before it is
proposed to commence work to ascertain whether any underground installations will be affected by
the proposed work, in which event the Main Contractor shall make all necessary arrangements with
the public utility authorities to safeguard the installation.
C. Follow up and Evaluation
Follow up on quality performance shall be carried out through in-house monitoring systems such as
progress reporting to the planning department, daily, weekly and monthly reports generated by the
planning department to closely monitor site performance. All the above shall be conducted in close
coordination with the quality department to monitor any deviations from the Quality Management
System requirement and induce corrective actions whenever required to eliminate non-conformance
or quality deviations.
D. RECORDS
Checklists (CKL)
Inspection Request (INR)
Other Project related reports.
12. ATTACHMENTS
A. Appendices
Appendix A: HSE Risk Assessment for Installation of Cable trays, ladders, and trunking
Appendix B: Inspection and Test Plan for Installation of Cable trays, ladders, and trunking
Appendix C: Checklist for Installation of Cable trays, ladders, and trunking
Appendix D: ITR-Earth Resistance and Continuity Test Report
Appendix E: Permanent Material Delivered Approval form
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METHOD STATEMENT FOR
INSTALLATION & TESTING OF
EARTHING, BONDING AND
LIGHTNING PROTECTION
SR. EFFECTIVE REV. MSS MANAGER MSS PROJECT CLIENT
CLIENT QA/QC
NO. DATE NO. QA/QC MANAGER SUPERVISOR
INSTALLATION & TESTING OF EARTHING, BONDING AND LIGHTNING PROTECTION
SCOPE
This Method Statement describes the sequence of activities involved in the installation of Earthing,
Bonding, and Lightning Protection as per the requirements derived from Scope of Work, Contract
Specifications, Codes and Standards of the project.
1. PURPOSE
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This Method Statement formalizes the requirements for Earthing, Bonding and Lightning protection.
The specifications, procedures, and guidelines contained in this Method Statement specify the
technical requirements to be followed and also act as a reference to clearly establish defined
standards for work assessment. Moreover, this document shall provide guidelines to check that
specified materials are installed and agreed procedures are implemented during the execution of work
and to define the responsibilities for controlling the execution.
2. SCOPE
This Method Statement describes the sequence of activities involved in the installation of
Earthing, bonding, and Lightning Protection as per the requirements derived from Scope of
Work, Contract Specifications, Codes and Standards of the project titled as under: “Name of Project
here”
3. DESCRIPTION
The main purpose of earthing in the electrical network is for safety. When all metallic parts in
electrical equipment are grounded then if the insulation inside the equipment fails there are no
dangerous voltages present in the equipment case.
To maintain the voltage at any part of an electrical system at a known value so as to prevent over
current or excessive voltage on the appliances or equipment.
Lightning, line surges or unintentional contact with higher voltage lines can cause dangerously high
voltages to the electrical distribution system. Earthing provides an alternative path around the
electrical system to minimize damages in the system.
An efficient earthing and lightning protection is to provide for Equipment Earthing, Fire Fighting
Equipment, Motors Earthing, Main Switchboards, Switchgears, and Motor Control Centres
Earthing, Distribution Boards Earthing, Bus-Duct Feeders Earthing, Cable Armour Earthing,
earthing for road lighting poles, columns, busbars, etc.
For Testing and Commissioning, a separate T & C Method Statement shall be provided by the T&C
department.
This method statement for earthing, bonding and lightning protection installation and testing can
be used in conjunction with the tower crane installation.
4. DEFINITIONS
Client – (Name of Client here)
Project Management – (Name of Project Management here)
Construction Supervision Consultant (CSC) – (Name of Consultant here)
Contractor – (Name of Contractor here)
Supplier/Vendor/Manufacturer – Seller of material as defined in the project specification
Must – Signifies a legal or statutory requirement
Shall – Signifies a requirement made mandatory by this specification
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May – Signifies a feature, which is discretionary in the context in which it is applied
Will – Signifies feature which the supplier may assume to be already present
5. REFERENCES
Specifications for Lightning Protection
Specifications for Earthing and Bonding
BS 7430 Code of Practice for Protective Earthing of Electrical Installations
BS 6651 Code of practice for protection of structures against lightning
IEEE 142 Grounding of Industrial and Commercial Power system
Approved material submittals
Approved shop drawings
6. ABBREVIATIONS
HSE – Health Safety and Environment
QA/QC – Quality Assurance and Quality Control
MST – Method Statement
RSK – Risk Assessment
ITP – Inspection and Test Plan
PQP – Project Quality Plan
INR – Inspection Request
PPE – Personnel Protective Equipment
T&C – Testing and Commissioning
7. RESPONSIBILITIES
A. General
1. Project Manager (MEP) will be responsible to manage, execute, complete and handover the
construction activities within approved budgets and resources in compliance with Project
Requirements as specified in Project Specifications. He will be overall in charge of implementing
Method Statement in accordance with QA/QC and HSE requirements.
2. Construction Manager will be responsible for managing construction activities and will lead and
communicate site Supervision, Subcontractors and Vendors to assist them in working to the Project
Schedule by conforming QA/QC and HSE requirements at the site.
3. HSE Manager will be responsible for plan, coordinate and implement issues and directives within the
organization. He ensures safe environmental working conditions for all employees.
4. QA/QC Manager will be responsible for supporting the project team in implementing and maintaining
Quality Management System for the project through PQP, ITP, MST, and Procedures in compliance
with Project specifications, Codes, and Standards.
5. HSE Officer will ensure enforcement of safety procedures in accordance with the approved HSE Plan.
Will be closely monitoring the site engineer’s strict implementation of the MS and Risk Assessment,
the use of proper tools and equipment to maintain safety, certifications of equipment and their
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adherence to safety regulations, reporting of any unsafe work or stopping work that does not comply
with HSE procedures.
6. Site Engineer will be responsible for carrying out all construction-related activities with compliance to
HSE and QAQC requirements as per contract specifications, drawings/documents, codes, and
standards.
7. QA/QC Engineer will be responsible for conducting inspections as per PQP.
8. Supervisor/Foreman will be responsible for coordinating all works and workers related to the job.
9. Electrician / other tradesmen will be responsible for assisting his superiors during all construction
work-related activities following HSE and QAQC requirements.
10. Store In-charge receives and inspects all incoming materials and reconciles with documents; processes
and distributes documentation; reports, documents, and tracks damages and discrepancies.
11. The security guard will be clearly visible, vigilant, respond quickly and correctly during the crisis,
observing and reporting, checking and monitoring, maintain order among workers, and offer safety
warnings and tips.
C. Interfacing with other operations
Other Mechanical, Electrical and Plumbing works and Architectural, Civil and Structural requirements
D. Duration, Phasing with the Subcontractors
All works associated with Construction work referred to in this Method Statement shall be completed
as per the project schedule.
E. List of Subcontractors
Main Contractor: (Name of Contractor here)
Subcontractors for MEP: (Name of Subcontractor here)
F. Handling and Storage
F-1. Workmanship
The laydown area shall be arranged for offload the materials prior to transport at the site.
The storage area shall be cleaned and is at a minimum height of 1 ft from the ground level. The
materials shall be stored in a shaded area to protect it from exposure of direct sunlight/rain etc.
Separate areas in the storage zone must be marked for different materials.
Slings used to lift the materials must be checked for damages and defects. Slings shall not be
shortened with knots and bolts or other makeshift devices. Slings should not be kinked and should not
be loaded in excess of their safe working load. Slings shall be padded or protected from the sharp
edges of their load.
All employees shall be kept clear of load about to be lifted and of the suspended load. Hands and
fingers shall not be placed between the slings and their load while the sling is being tightened around
the load. Slings shall not be pulled from under a load when the load is resting on the sling. Always use
two-point loading to avoid load slipping.
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The forklift must be third-party certified and fit for the purpose. Ensure that forklift operators must be
qualified, trained and with a valid license. Ensure daily inspection of forklifts has carried out prior to
commencement of work.
F-2. Responsibilities
The Store Incharge shall ensure that all approved supplies be delivered to the site as per the approved
material submittal with the manufacturer’s seals, labels or other proof of origin intact. These labels
and seals shall not be removed until the material is required for use and shall be retained for
inspection by the Consultant and QAQC.
Each material item shall be allotted a distinct and separate reference number and mentioned on
material requisition. Make sure that material is approved/examined by the Consultant and QAQC and
associated documents/test certificates are approved.
The Site Engineer shall be responsible for the off-loading and handling of the materials on-site and
shall ensure that materials delivered to the site are properly protected against mechanical damage.
8. RESOURCES
A. Tools and Equipment
1. Electrician hand tools set.
2. Multimeter
3. Electric resistance tester
4. Continuity tester
5. Screwdriver sets
6. Cable cutter
7. Calibrated Megger.
8. Crane
9. Forklift
Note:
All testing equipment and measuring tools to be used shall have valid calibration certificates prior to
usage.
All lifting equipment and machines shall be 3rd party verified with valid certificates.
B. Materials
The material shall be used after being approved by Approved Material Submittals. Generally, the
following material items shall be used during installation. Earth Continuity Conductors, Main Earth
Loops, Rod Electrodes, Earth Connectors, Removable Earth Links, Bolts, Washers and Nuts, and Earth
Pit Cover.
C. Site Preparation and Planning
C.1 Preparation
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The contractor shall ensure that all gate passes, permits, tools, materials for safety
precautions, manpower and equipment are available before commencement of work. The Site Team
shall make sure that access roads are always clear from any obstruction and site is always accessible.
C.2 Site clearance
Before commencing the work, the area shall be cleared of all debris, materials or other obstructions.
C.3 Traffic Management
The Site Team with the assistance of the Safety Officers shall coordinate logistics and materials
movement through site following the direction and road signs displayed on site. The required diversion
routes shall be marked on drawings including the required traffic signs. The Work Permits and
Operator Certificates shall be compiled and files for reference by authorized personnel. Temporary
traffic signs, barriers, and flagmen will be deployed to control traffic flow in accordance with and
Traffic Management of the HSE Plan. At the end of each ramp, there will be a transition area to give
the driver the opportunity to watch the access roads before joining thereto.
C.4 Pre-construction Safety Meetings:
The meeting shall be scheduled prior to the beginning of the work and before any Subcontractor starts
on the project.
Safety awareness meetings will be conducted every working day morning/every other day to brief the
workforce in safety prevention measures. The equipment check for safety shall be recorded/
documented during the daily Safety Awareness Meeting. Traffic safety will be discussed to emphasize
these meetings.
Each worker will be instructed to follow specific safety requirements related to his trade.
They will be required to follow installed safety signs, observe barricades and use PPEs.
Contractor Safety will perform hazard risk analysis by identifying all steps, hazards identified in those
steps, with a focus on the relationship between the work task, the tools, and the work environment.
After identifying uncontrolled hazards; the Contractor will take steps to eliminate or reduce them to an
acceptable risk level.
General Contractual Safety, Health, and Environmental requirements.
Roles of the contractor, subcontractors, authorized representatives, and all project workers.
Accident reporting requirements.
Specific details of the work to be performed along with the use of personal protective equipment.
Emergency procedure.
C.5 Operating Procedures:
A site investigation has to be carried out to develop safety precautions and measures prior to the
commencement of the work. After such investigation, relevant signboards will be displayed and
barricades will be installed where and as necessary, such as but not limited to the following:
Relevant information, advanced signs, warning, and mandatory signs will be placed as required.
Radio Communication system would be used where normal communication is impossible.
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After completion of the work, safety cones and barricades have to be removed accordingly.
9. PROCEDURE
A. Pre Installation
All relevant documentation, approved shop drawings and material applicable to a particular section of
works will be checked by Site Engineer prior to commencement of work.
Ensure that Material received is in compliance with the project specifications and is approved.
Ensure that all required materials and accessories are delivered, inspected and approved by Consultant
and are readily available at the site to carry out the work.
Prior to the commencement of work, areas and access will be inspected to confirm that the site is
ready to commence the work.
All relevant documentation, approved shop drawings and material applicable to a particular section of
works will be checked by Site Engineer prior to commencement of work.
The Site Engineer/Site Supervisor will give necessary instructions to tradesmen (Electrical) and provide
necessary approved construction/shop drawings.
The Site Engineer/Site Foreman will check that proper tools and equipment are available to carry out
the work and are in compliance with contract specifications.
The Site Engineer will explain his team about HSE precautions to be observed.
The Site Engineer/Foreman ensures the cleanliness of the area.
B. Installation
B.1 Installation of Earthing and Bonding:
B.1.1 Bolted Connection
1. Circuit Wiring shall have a green/yellow colored insulated earth continuity cable connecting the earth
bus or earth terminal in switchboards, switchgear, motor control centers, and panel boards to the
motor, equipment, outlet and other devices by earthing lugs. All handrails and other metal works
within 2 m of a potentially live metal surface shall be earthed.
2. For Main Earth Loops the following shall be fixed.
Copper tape to structure with copper or brass saddles and/or screws. Make tees and straight joints by
riveting and seating.
In mechanical equipment rooms and other areas indicated on the drawings, in convenient locations,
allowing two return paths to earth.
Prepare branch connections between the main loop and major equipment, such as switchboards,
switchgear, motor control centers, and large motors, with copper tape as main loop tape. Make other
branch connections to equipment with copper conductors of size not less than half that of the relative
phase conductor.
Removable Earth Links shall be installed in an accessible position, above ground as close as possible to
the earth electrode. Also, fix in every main earth lead to enable the electrode system to be
disconnected for testing.
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Exposed Earth Cables; install and locate in a manner to provide maximum mechanical protection,
utilizing ceiling corners, suspended ceiling & webs of beams as much as possible.
Bolted Connections: Multiple bolt type. Where bare copper is bolted in connections contact surfaces
shall be silver electroplated.
Where earthing terminal connections are to be brazed to equipment, thoroughly clean metal prior to
brazing and repaint impaired surfaces to prevent corrosion.
Connections Between Dissimilar Metals shall be protected by painting with a moisture-resistant
bituminous paint/compound or wrapping with protective tape to exclude moisture.
Equipment Earthing; Connections shall be made for all non-current carrying metallic parts of the
electrical/mechanical installation to the earthing system. Series earthing of one piece of equipment to
another is not acceptable. Each item shall be individually connected to the earth system.
For Fire Fighting Equipment, earth on a separate ring system.
For Motors Earthing the motor terminal box shall be connected to the relative earth loop. The terminal
must be mechanically connected to the frame or, where this is not feasible to extend the earthing
conductor through an insulated bushed opening in the connection box and connect to the frame.
For the Earthing of Main Switchboards, Switchgears and Motor Control Centres connection shall be
followed in a manner that connects the special earthing lug or busbars inside the cabinet to the main
earth copper tape.
Distribution Boards Earthing shall be connected in such a way that earthing conductor from the main
distribution earth busbar shall be connected to an earth connector welded to the cabinet and earthing
bushings on the incoming and outgoing feeder conduits.
For Bus-Duct Feeders Earthing, the connection shall be like that of the green/yellow coded earth
busbar directly to the earth bus-bar in the main switchboard with earth copper tape.
For Cable Armour Earthing, steel armor shall be connected to the earthing system.
Earth Rod electrodes (extensible rods) of the same diameter shall be installed in holes drilled into the
ground. If ground conditions permit, rods may be driven into the ground either
manually/mechanically. The earth electrode shall be installed at a reasonable depth.
A concrete/PVC earth pit, cast iron or PVC cover shall be provided (after approval), at the head of the
earth rod, to protect the rod and allow access to connections for testing.
The resistance of any point in the earth’s continuity system to the main earth electrode shall not
exceed 1 ohm unless approved otherwise by Authorities.
Bonding shall be provided for all metallic conduits and trunking, cable trays. Also for all electrical
devices and equipment with accessible metallic parts including cabinets and lighting fixtures.
B.1.2 Welded Connection
1. Exothermic Welding. Bare Copper cables shall be laid under the foundation structure of the building,
directly below blinding in direct contact with the soil and main earthing conductors are connected to
earth mesh.
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Where bare copper is welded as per approved design and calculations, the following steps to be
followed as per the manufacturer’s recommendations.
Exothermic welding is a simple method of making permanent, very high-quality electrical connections.
The process uses the high-temperature reaction of copper oxide and aluminum, within a semi-
permanent graphite mold, to form electrical connections mainly between copper to copper or copper
to steel.
No outside source of power or heat is required. Making a joint is a simple procedure that requires a
mold, weld powder, handle clamp, retaining disks, flint gun and various tools and cleaning accessories.
The steps are the following: (Refer to the diagram for details.)
Position cleaned conductors in the mold after ensuring mold is dry, by pre-heating or making a test
joint.
Lock mold with handle clamp and place metal retaining disc in the bottom of mold crucible.
Pour weld powder into the mold and place a small amount of starting powder on edge of mould for
easy ignition.
Close mold lid securely.
Ignite starting powder using a flint gun.
The reaction takes place. Wait several seconds to allow the metal to solidify before opening mold.
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Remove weld and clean mold carefully before making the next connection.
Installation of Lightning Protection:
o Removable Earth Links shall be fixed in every main earth lead to enable the electrode system to be
disconnected for testing. These shall be installed in an accessible position, above ground as close as
possible to the earth electrode.
o Bolted Connections shall be multiple bolt types and where bare copper is bolted in connections
contact surfaces shall be silver electroplated.
o Where connections between dissimilar metals, it shall be protected by painting with a moisture-
resistant bituminous paint or compound or wrapping with protective tape.
o Extensible rods of the same diameter shall be installed in holes drilled into the ground. If ground
conditions permit, rods may be driven into the ground either manually or mechanically. The earth
electrode shall be installed at a reasonable depth that penetrates the summer water table by a
minimum of 2 meters. Under no circumstances shall lightning protection electrodes be connected to
an earthing electrode. A minimum distance of 7 meters shall be provided between any lightning earth
electrode and earth electrode.
o Weld earth connectors to top of rods, insufficient to make the connection with incoming cables.
o A concrete/PVC earth pit, cast iron or PVC cover shall be provided (after approval), at the head of the
earth rod, to protect the rod and allow access to connections for testing.
10. HEALTH, SAFETY, AND ENVIRONMENT
A. HSE Risk Assessment
Please refer to the attached document in Appendix A.
B. Permit and Licensing Requirements
The required permit to work shall be obtained prior to the commencement of work. This shall be
coordinated with HSE.
C. Pre-Start Safety Briefing Arrangements
C.1 Protective and Safety Equipment
All workers Involved shall be equipped with adequate PPE as stated below:
Safety Helmet with Company Logo
Safety Boots
High Visibility Vest
Safety Goggles
Hand Gloves
Coveralls
High voltage gloves
High voltage Rubber Mat
Proper safety harness
C.2 Information to Personnel
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REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 482 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
Safety Induction
Job training
Superintendents Notices/Memos
Toolbox talks
STARRT Card
C.3 Special Safety Requirements:
All necessary personal/protective equipment (PPE), as well as a harness, to be provided.
Rigging Team, wearing distinctive vests, shall be assigned to help operators maneuver the equipment.
The equipment operators shall possess the required licenses and certificates.
Generated dust shall be controlled by periodic water spraying.
The required permit to work shall be obtained prior to the commencement of work.
The project safety officer is responsible along with the project zone site engineer for ensuring that all
operations are carried out with due regard to the safety of all project personnel & property.
Working at height to be monitored with due care.
In case of working at night, please refer to Method Statement for Night Works
Emergency Procedures
11. QUALITY ASSURANCE AND QUALITY CONTROL
A. Quality Assurance Requirements
The contractor shall provide the required documents for the Consultant’s approval prior to initiating
the execution of this activity as per project Specification.
The Quality Control requirement shall include related to ITP’s and other related documents as
applicable.
Refer to Inspection Test Plan (See Attachment B)
Applicable codes and standards referenced for materials and installation in MS.
Project Specifications
B. Quality Assurance Process
The contractor shall notify the Engineer 24 hours in advance prior to the start of activity
and Comments from the site Instruction will be complied with the satisfaction of the consultant.
C. Follow up and Evaluation
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Follow up on quality performance shall be carried out through an in-house monitoring system such as
progress reporting to the planning department, daily, weekly and monthly reports generated by the
planning department to closely monitor site performance in general and reflect on quality
performance in specific.
All the above shall be conducted in close coordination with the quality department to monitor any
deviations from the Quality Management System requirement and induce corrective actions whenever
required to eliminate non-conformance or quality deviations.
D. Records
Inspection and Test Reports (ITR)
Checklists (CKL)
Inspection Request (INR)
Other Project related reports.
12. ATTACHMENTS
Appendices
Appendix A: HSE Risk Assessment
Appendix B: Inspection and Test Plan
Appendix C: Checklist for Earthing-Above Ground Installation
Appendix D: Checklist for Earthing -Under Ground Installation
Appendix E: Checklist for Lightning Protection Installation
Appendix F: Inspection & Test Report- Earth Resistance & Continuity Test
Appendix G: Permanent Material Delivered Approval Form
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METHOD STATEMENT FOR
FALSE CEILING WORKS
(GYPSUM BOARD AND TILE CEILING)
SR. EFFECTIVE REV. MSS MANAGER MSS PROJECT CLIENT
CLIENT QA/QC
NO. DATE NO. QA/QC MANAGER SUPERVISOR
FALSE CEILING WORKS
1. PURPOSE
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This method statement for false ceiling describes the details of the installation of suspended gypsum
board and tile ceiling with the use of metal framings in the project. This also outlines the health and
safety hazards involved and include the guide on how to do the process safely.
A false ceiling or alternatively called drop ceiling is a fixed framework made of either aluminum, metal
or wooden batten covered with either material like Plaster of Paris, gypsum board, plywood, PVC
sheets, wood, metal ceiling tiles, glass, mineral fiber, etc. hung below the main ceiling.
2. TABLE OF CONTENTS
1. SCOPE & OBJECTIVES
2. REFERENCES
2.1. Contract documents
2.2. Contractors Submittal
3. DEFINITIONS / ABBREVIATIONS
3.1. Definition
3.2. Abbreviations
4. RESPONSIBILITIES/SUPERVISION
5. EQUIPMENTS & TOOLS / MANPOWER / MATERIALS
5.1. Plant & Equipment Requirement
5.2. Manpower Requirement
5.3. Material Requirements
6. PROCEDURE / METHOD TO BE EMPLOYED
6.1. Site survey
6.2. Setting Out
6.3. Fixing Of Wall Angles
6.4. Fixing Of Hangers
6.5. FrameWork
6.6. FrameWork Inspection and MEP Clearance
6.7. Taping and Jointing For Gypsum Board Ceilings
6.8. Final Check-Up
6.9. Cleaning and Handover to the Main Contractor
7. HEALTH AND SAFETY HAZARDS:
8. ATTACHMENTS
8.1. Inspection Checklists
8.2. Inspection Test Plan
8.3. Risk Assessment
8.4. Technical Datasheet (TDS)
8.5. Material Safety Data Sheet (MSDS)
3. SCOPE & OBJECTIVES
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This method statement describes the method of installation of suspended gypsum board and tile
ceiling with the use of metal framings in the project.
4. REFERENCES
4.1. Contract documents
1. Project Specification:
2. Contract Drawings:
4.2. Contractors Submittal
3. Project Quality Plan:
4. Project Safety Plan:
5. Material approvals (MAT)
6. Shop Drawings approvals (SPD)
7. Related method statements (MET)
5. DEFINITIONS / ABBREVIATIONS
5.1. Definition
1. Project –
2. Client –
3. Developer –
4. Consultant –
5. PMC –
6. Contractor –
7. Sub-contractor -
8. Supplier –
5.2. Abbreviations
1. Engineer – Representative of “Name of engineering consultancy”
2. ICL – Inspection Check List
3. IR – Inspection Request
4. ITL -Independent Testing Laboratory
5. ITP – Inspection and Test Plan
6. ITR -Inspection & Test Requests
7. MAT – Material Submittal
8. MEP – Mechanical Electrical Plumbing
9. MET – Method Statement
10. MIR – Material Inspection Request
11. MSDS – Material Safety Data Sheet
12. PPE -Personal Protective Equipment
13. PQP -Project Quality Plan
14. PTW -Permit To Work ( Working at Height or enclosed spaces)
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15. RA -Hazard Identification and Risk Assessment
16. RFIA – Request for Inspection and Approval
17. SPD – Shop Drawing
18. TBM – Temporary Bench Mark
6. RESPONSIBILITIES/SUPERVISION
1. The project manager of the subcontractor is overall responsible for the implementation of the MS.
He will ensure that the supervisory staff allocated for this MS and all resources are in place
2. The site engineer is responsible to execute the installation work as per the approved MS. QA/QC
engineer of the subcontractor is responsible to ensure that work has been done as per specification
and inspections are done as per the approved ITP. Safety officer of the subcontractor is responsible to
ensure that all personnel on site are to abide by the project safety requirements.
7. EQUIPMENTS & TOOLS / MANPOWER / MATERIALS
7.1. Plant & Equipment Requirement
Following tools will be used for installation of suspended false ceiling works.
1. Drills with bits for concrete and metal
2. Screw gun – Power tool that drives all types of gypsum board screws through gypsum board and
into framing or substrate
3. Powder-actuated tool ( E.g. Hilti Gun fastener)
4. Chalk line
5. Sprit level
6. Metal cutting scissors
7. Measuring tape – A steel retractable measuring tape, usually 25 feet in length.
8. Gypsum board T-square –Square edge for measuring and cutting gypsum board to length and for
cutting out holes for square outlet boxes and other openings.
9. Utility knife – the Standard cutting tool with replaceable/reversible blades for scoring and cutting
gypsum board.
10. Hammer – Drives nails through gypsum board into wood framing.
11. Keyhole saw – Small triangular saw for cutting out holes for outlet boxes, pipes, and other
penetrations.
12. Assorted trowels and taping knives – Bladed tools for applying and smoothing tape and joint
compound over joints and fastener heads.
13. Tray / Box to contain joint compound while finishing joints and fastener heads.
7.2. Manpower Requirement
1. False ceiling technician
2. Labour
3. Supervisor/ Foreman
4. Site Engineer
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7.3. Material Requirements
Following materials will be used for installation of suspended false ceiling works.
1. 12.5mm thick regular gypsum boards
2. 600x600x6mm thick calcium silicate tiles
3. 0.55mm thick suspension of framing elements
4. T-24 exposed GI suspension
5. 0.5 mm thick 600mm x 600mm Aluminum tile
6. Main Runners and Furring Channels of 0.55mm thick
8. PROCEDURE / METHOD TO BE EMPLOYED
8.1. Site survey
1. The receipt of the shop drawings approved the consultants the site will be surveyed and any
discrepancy found will be notified to the main contractor for clarification.
8.2. Setting Out
1. Setting out and marking will be done as per approved shop drawing ceiling height of various areas
shall be marked based on the benchmark provided by main contractor level will be transferred on all
the corners and chalk lines will be marked.
8.3. Fixing Of Wall Angles
1. The wall angles will be fixed along the marked ceiling line depending on the substrate at 600mm to
center spacing. Before fixing the wall angle the substrate has to receive necessary finishes as per the
finish schedule.
8.4. Fixing Of Hangers
1. Fixing of hangers will be done as per the approved shop drawing layout details and using hanger
anchorage devices of the soffit as per approved material submittal. The position of the hangers will be
marked on the soffit of the slab, which has to be reviewed by main contractor site engineer upon
receipt of MEP clearance hangers shall be fixed at a spacing of 1200mm centres on both the directions
where MEP services are clashing with fixing hangers, additional supplies shall be provided by agreeing
with main contractor on site.
8.5. Frame Work
1. The framework will be done according to the approved shop drawings and with approved materials.
Framing members such as Main Runners and Furring Channels of 0.55mm thick shall be placed as a
spacing of 1200mm and entries respectively. Heavy recessed fixtures should be independent of the
ceiling framing stems.
8.6. FrameWork Inspection and MEP Clearance
1. Upon completion of framework, respective areas shall be offered for main contractor and consultant
inspection. Inspection request will be raised on prescribed formats for first and second fix of ceiling.
Written clearance for MEP and associated works to be different stages for the uninterrupted flow of
our works. Upon receiving the approval and MEP clearance. Void closures shall be started by gypsum
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board installation. Gypsum boards of specified type (Regular) shall be applied to the framing using
gypsum screws at 200mm. For tile ceiling, the void closure will be done by placing calcium silicate tiles
on the complete grid work.
8.7. Taping and Jointing For Gypsum Board Ceilings
The following coat will be applied over the joints.
1. First Coat / Jointing Coat
2. Second Coat
3. Third Coat
1. First coat is initial jointing process where the fiber tape is fixed over the thin joining compound
applied over the joints. Another layer of jointing compound application would be done over the tape.
This would be approximately 75mm wide. Screw heads also will be covered by the application of the
joint compound. The second and third coat will be applied successively after having dried the previous
coats. Each successive coat to be feathered 40mm beyond the previous layer sides of the joint. This
would be sanded smooth after drying and leave for receiving decoration by following trades.
8.8.Final Check-Up
On completion of taping, jointing and sanding subcontractor supervisor will check the level and make
sure that is in true level and the work is within the tolerance limits.
8.9. Cleaning and Handover to the Main Contractor
1. When all our activities are completed, the area will be clean thoroughly. Once the cleaning is done
and approved subcontractor’s site in-charge a “Request for inspection” could be raised by him to main
contractor for their acceptance to issue the substantial completion of works certificate. The area then
would be handed to the main contractor or the succeeding contractor for further finishes/decoration.
9. HEALTH AND SAFETY HAZARDS:
Specific safety measures have to be followed as applicable, and all the safety measures are covered
separately in the Project Safety Plan.
10. ATTACHMENTS
10.1. Inspection Checklists
10.2. Inspection Test Plan
10.3. Risk Assessment
10.4. Technical Data Sheet (TDS)
10.5. Material Safety Data Sheet (MSDS)
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METHOD STATEMENT
OF POTABLE WATER/FIRE WATER
NETWORK INSTALLATION
SR. EFFECTIVE REV. MSS MANAGER MSS PROJECT CLIENT
CLIENT QA/QC
NO. DATE NO. QA/QC MANAGER SUPERVISOR
POTABLE WATER/FIRE WATER NETWORK INSTALLATION
1. PURPOSE
This method statement of potable water/firewater networks defines the installation and testing as per
specifications, procedures, & HSE requirements. This method statement specifies the technical
requirements to be followed and also acts as a reference to clearly establish defined standards for
work assessment.
Moreover, this document shall provide guidelines to check that specified materials are installed and
agreed procedures are implemented during the execution of work. This also defines the
responsibilities for controlling the execution.
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2. SCOPE
This Method Statement describes the sequence of activities involved in laying and testing of potable
water / firewater network as per the requirements derived from the scope of work, contract
specifications, codes, and standards of the project.
3. DESCRIPTION
All activities for earthwork, trench excavation, pipe bedding in trenches, backfilling after laying the
piping, laying of marker tapes, and all associated jobs relates to civil shall be done by a civil contractor
whose prequalification documents shall be forwarded to authority for approval prior to
commencement of any activity whatsoever.
Work includes the construction of potable water/firewater network including installation of ductile
iron piping, valves and other appurtenances, fire hydrants, hydraulic testing of pipelines, swabbing,
flushing, and disinfection.
Moreover, corrosion protection of all metallic parts of the network will be part of this MST whilst
construction of the different types of valve chambers as well as other reinforced concrete structures is
excluded.
4. DEFINITIONS
Supplier/Vendor – Seller of material as defined in the project
Must – Signifies a legal or statutory requirement
Shall – Signifies a requirement made mandatory by this specification
May – Signifies a feature, which is discretionary in the context in which it is applied
Will – Signifies feature which the supplier may assume to be already present
5. REFERENCES
Approved material submittals
Approved shop drawings.
General Specification for Main Laying Materials for Water
General Specification for Main Laying Contracts
Main Laying Design Standards
British Standard 6920 – Testing of Non-Metallic Components with Regard to their effect on the Quality
of Water (Items which have passed full tests of effect on water quality.)
Project Specification
AWWA C600 Installation of Ductile-Iron Water Mains and Their Appurtenances
6. ABBREVIATIONS
HSE Health Safety and Environment
QA/QC Quality Assurance and Quality Control
MST Method Statement
RSK Risk Assessment
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ITP Inspection and Test Plan
PQP Project Quality Plan
INR Inspection Request
PPE Personnel Protective Equipment
MEP Mechanical, Electrical & Plumbing
STARRT Safety Task Analysis Risk Reduction Talk
FF Flat Face
DI Ductile Iron
PN Nominal Pressure
DN Nominal Diameter
RF Raised Face
AWWA American Water Works Association
ASME American Society of Mechanical Engineers
ASTM American Society of Testing and Materials
MDPE Medium Density Polyethylene
WRAS Water Regulation Advisory Scheme
EPDM Ethylene Propylene Diene Monomer
NTC Non-Toxicity Certificate
BFV Butterfly Valve
GV Gate Valve
ARV Air Release Valve
DFM District Flow Meter
FCV Flow Control Valve
NRV Non-Return Valve
FH Fire Hydrant
7. RESPONSIBILITES
A. GENERAL
1. Project Manager (MEP) will be responsible to manage, executing, completing, and handover the
construction activities within approved budgets and resources in compliance with project
requirements as specified in project specifications. He will be overall in charge of implementing
the method statement in accordance with QA/QC and HSE requirements.
2. Construction Manager will be responsible for managing construction activities and will lead and
communicate site Supervision, Subcontractors and Vendors to assist them in working to the project
schedule by conforming QA/QC and HSE requirements at site.
3. HSE Manager will be responsible for planning, coordinating, and implementing issues and directives
within the organization. He ensures safe environmental working conditions for all employees.
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4. QA/QC Manager will be responsible for supporting the project team in implementing and
maintaining Quality Management System for the project through PQP, ITP, MST, and procedures in
compliance with project specifications, codes, and standards.
5. HSE Officer will ensure enforcement of safety procedures in accordance with the approved HSE Plan.
Will be closely monitoring the site engineer’s strict implementation of the MST and Risk Assessment,
the use of proper tools and equipment to maintain safety, certifications of equipment and their
adherence to safety regulations, reporting of any unsafe work or stopping work that does not comply
with HSE procedures.
6. Site Engineer will be responsible for carrying out all construction-related activities with compliance to
HSE and QAQC requirements as per contract specifications, drawings/documents, codes, and
standards.
7. QA/QC Engineer will be responsible for conducting inspections as per PQP.
8. Supervisor/Foreman will be responsible for coordinating all works and workers related to the job.
9. Electrician / other tradesmen will be responsible for assisting his superiors during all construction
work-related activities following HSE and QA/QC requirements.
10.Store In-charge receives and inspects all incoming materials and reconciles with documents;
processes and distributes documentation; reports, documents and tracks damages and
discrepancies.
11.Security guards will be clearly visible, vigilant, respond quickly and correctly during the crisis,
observe and report, check and monitor, maintain order among workers, and offer safety warnings
and tips.
B. MATERIAL HANDLING AND STORAGE
All materials shall be handled/transported/stored in an optimal way that will not cause damage to
them.
During transport, special care shall be taken not to damage the coating of the materials. Materials
shall be cleaned from any foreign matter deposited during transport.
All materials to be stored are strictly in accordance with the requirements/manufacturer storage
recommendation. At all times, all corrosion protection materials shall be stored under the shade and
not be exposed to direct sunlight.
Upon delivery to the contractor’s stores or site, the contractor should unpack at all times, open all
crates, etc., and unload to areas as directed by the Store controller or the Site Engineer. The
contractor shall provide all timbers and packing, necessary for the correct stacking of pipes, fittings,
and other delivered materials.
After inspection, the contractor shall shift and stack the approved materials to areas as directed by
the store controller/ site engineer.
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All coated materials such as epoxy etc. shall be handled special care during transportation/loading in
order to protect from accidental damage. Use hooks with special protection of plastic or rubber to
avoid damage to the internal coating of the pipe.
The storage area for DI pipes and fittings has to be arranged with a leveled wooden platform. The
area should be barricaded.
The DI pipes and fittings should be laid on the wooden platform, in a horizontal position only. Care to
be taken that the pipes are arranged in order of dimension.
Larger-sized pipes of thicker class shall always be stacked at the bottom level.
The ends of pipes should be kept closed by means of the manufacturer-supplied plugs.
The layer of pipe stacks will be in accordance with the manufacturer’s storage and handling
recommendations.
The gaskets and all other accessories/fittings should be stored in a cool and dry place and should be
protected from direct sunlight and moisture. It should be stored in a normal position, free from any
deformation.
The storage area shall be cleaned and is at an appropriate height from the ground level. The
materials shall be stored in a shaded area to protect them from exposure to direct sunlight/rain etc.
Separate areas in the storage zone must be marked for different materials.
Ensure when the transporting load for the fork should not raise more than 8 inches from the ground
and the load should be titled back, never carry loose or poorly stacked loads. Never put hands or legs
in the lifting.
Whenever heavy or bulky material is to be moved, the material handling needs will be evaluated in
terms of weight, size, distance, and path of movement.
Each material item shall be allotted a distinct and separate reference number and mentioned on the
material requisition. Make sure that material is approved/examined by the Consultant and QA/QC
and associated documents/test certificates are approved.
The Store In-charge shall ensure that all approved supplies be delivered to the site as per the
approved material submittal with the manufacturer’s seals, labels, or other proof of origin intact.
These labels and seals shall not be removed until the material is required for use and shall be
retained for inspection by the consultant and QA/QC.
The Site Engineer shall be responsible for the off-loading and handling of the materials on-site and
shall ensure that materials delivered to the site are properly protected against mechanical damage.
No metallic strings or chains shall be allowed for lifting/ handling DI pipes and fittings. Only cloth or
similar belts shall be used for such purpose.
Molding putty and wrapping tapes shall be kept/ stored in a cool place. Polyethylene sheets shall be
dealt with in a similar way so as to avoid being degraded as a result of exposure to direct sunlight.
C. MATERIAL INSPECTION
For materials to be inspected after receiving at the site, the following points are to be followed:
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 496 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
On receipt of materials at the site, necessary precautions shall be taken for unloading, shifting, and
storage.
Each material item shall be allotted a distinct and separate reference number and mentioned on the
material requisition. Make sure that material is approved/examined by the Consultant and QA/QC
and associated documents/test certificates are approved.
The Store In-charge shall ensure that all approved supplies be delivered to the site as per the
approved material submittal; with the manufacturer’s seals, labels, or other proof of origin intact.
These labels and seals shall not be removed until the material is required for use and shall be
retained for inspection by the Consultant and QA/QC.
I/C Stores shall initiate material inspection for all incoming material to QA/QC and the material shall
be inspected against reference documents and as per approved material submittal. Moreover, the
physical condition of the material shall be checked. Afterward, an INR shall be raised by QA/QC to the
consultant and inspection will be carried out by the Consultant.
Materials, which do not conform to the given specification/approved material submittal, shall be
rejected. Any discrepancy or damages will be notified and reported for further action.
The material found not suitable for site use will be removed from the site and arrangements shall be
made for replacement.
For any materials inspection (especially pipes, fittings, valves, other accessories), the items shall be
segregated as per their type/sizes and placed items separately in racks or on different pallets.
Each rack/pallet shall have an identification posted on a laminated paper with the description of the
items clearly written on it.
There shall be appropriate spaces between the pallets so that the engineer/inspector can freely go
around them and inspect the materials thoroughly.
Staking the materials all over each other & in one corner is strictly not allowed.
All items shall be kept in a protective environment and shall not be kept directly on the floor; they
shall have wooden pallets underneath them.
Primer/paints shall never be kept under direct sunlight or exposed to a harsh site environment. They
shall be stored in an air-conditioned environment inside the warehouse.
If the items in one pallet are more in number, do not arrange them on top of one another, and
provide space in between to inspect easily.
Generally, after the inspection request is approved by the consultant, an invitation to Material
Engineer shall be forwarded through the Project Manager & the client for final inspection and
permission to use.
8. RESOURCES
A. TOOLS AND EQUIPMENT
Tools
a. Mechanics Toolbox
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Page 497 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
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NAME:
b. Drilling Machine
c. Spirit Level
d. Grinding / Cutting Machine
e. Chain Block
f. Pipe Wrench
g. Torque Wrench
h. Feeler gauges
Equipment
a. Trailer to accommodate pipe length of 6 meters
b. 25-30 Tons Crane
c. 2-3 Tons Forklift
d. Belts
e. Chain Block
f. Hydrostatic testing equipment includes test pump and test manifolds, two calibrated pressure
gauges.
Note:
All testing equipment and measuring tools to be used shall have valid calibration certificates prior to
usage.
All lifting equipment and machines shall be 3rd party verified with valid certificates.
B. MATERIALS
a. The material shall be used after being approved by approved material submittals.
b. All material to be used shall conform to the project specification and authorities regulations
(where required).
C. LIST OF MANPOWER
Construction Manager
Pipe installers
QA/QC Engineer
Helpers
HSE Officer
Mobile Crane Operator
Site Engineer
Trailer Driver
Supervisor
Forklift Driver
Foreman
Riggers
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Page 498 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
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NAME:
9. METHODOLOGY-POTABLE WATER/FIREWATER NETWORK INSTALLATION AND TESTING
Nominal Bore Maximum Trench
Nominal Bore mm Maximum Trench Width mm
mm Width mm
100 550 600 1350
150 600 800 1550
200 800 1000 2000
300 900 1200 2300
400 1000 1400 2500
500 1250 1500 2700
A. PRE INSTALLATION
All activities for earthwork, trench excavation, pipe bedding in trenches, backfilling after laying the
piping, laying of marker tapes, and all associated jobs related to civil discipline shall be done by the
civil contractor.
Check & verify that the civil work is completed in compliance with all requirements for installation as
per approved shop drawing and handed over for mechanical works. Joint inspection of the location
shall be carried out by the consultant & contractor before releasing the excavated trench for
installation works.
Any over-excavation adjacent to a structure or beneath the formation level of a pipeline either to be
constructed under the contract or in a futures contract shall be backfilled with grade 20 SRC
concrete.
If during excavation the trench width exceeds one of the values listed in the table below:
A plain or reinforced concrete cradles and/or reinforced concrete arches shall be provided to the
requirements shown on the drawings and to the approval of the engineer.
Check the pipe for transport damage prior to starting with any installation work; Check that the
inside of the materials is free from any foreign objects.
Transport and unload the pipe, fitting & support down to its intended installation place.
Pipe installers should be careful to prevent bending or torsion strains from being applied to flanges
or flanged appurtenances.
Ensure that proper and dry trench beddings are placed.
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TITLE:
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Page 499 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
Verify that the invert levels of the trench are correct. Check the dimensions and elevations based on
the approved benchmark by the engineer.
Ensure trenches are free from obstruction, rocks, and other debris prior to laying of the ductile iron
materials.
All relevant documentation approved shop drawings, and material applicable to a particular section
of work will be checked by Site Engineer prior to commencement of work.
Ensure that material received is in compliance with the project specifications/authorities regulations
and is approved. Ensure that all required materials and accessories are delivered, inspected, and
approved by the consultant and are readily available at the site to carry out the work.
Prior to the commencement of work, areas and access will be inspected to confirm that site is ready
to commence the work and coordinated with other trades and subcontractors.
All relevant documentation (including MST and RA are approved, obtain necessary work permits, fill
up STARRT cards after completion of daily toolbox talk), will be checked by Site Engineer prior to
commencement of work.
The Site Engineer/Site Supervisor will give necessary instructions to mechanical tradesmen and
provide necessary approved construction/shop drawings.
The Site Engineer/Site Foreman will check that proper tools and equipment are available to carry out
the work and are in compliance with contract specifications.
The Site Engineer will explain to his team about HSE precautions to be observed.
The Site Engineer/Foreman ensures the cleanliness of the area.
Pre‐inspection arrangements for DI pipes, fittings, valves, and corrosion protection materials: In
order to facilitate the onsite inspection for Materials Engineers, the following points are to be
followed.
For any materials inspection, the items shall be segregated as per their type/sizes on different pallets.
Each pallet shall have the description of the items clearly displayed on it.
There shall be appropriate spaces between the pallets so that the engineer/inspector can freely go
around them and inspect the materials thoroughly.
Staking the materials all over each other & in one corner is strictly not allowed.
All valves shall be kept under the shade away from direct sunlight. The valves shall not be kept on the
floor; they shall have wooden pallets underneath them.
Corrosion protection materials shall never be kept under direct sunlight or exposed to a harsh site
environment. They shall be stored inside the site warehouse.
If the items in one pallet are more than ten in number, do not arrange it on top of the others, and
provide space in between to inspect easily.
B. PROCEDURE
All necessary work permits shall be obtained prior to the commencement of any activity at the site
and shall remain valid throughout the entire duration of the operation.
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Page 500 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
Work clearance forms shall be submitted and approved prior to commencement of any works at the
site.
The work area shall be isolated by erecting suitable barricades.
At the completion of each day’s pipe laying, the ends of the pipe shall be covered to prevent the
ingress of dirty water or debris.
Prior to the start of excavation, make sure that the pipeline coordinates and elevation have been
certified by the surveyor. Pipe location, elevation, and slope shall be maintained by a surveyor. A
survey report shall be made after the final installation.
For the waterlogged areas, gabbro material as gravel shall be used.
Before the start of pipe laying, the bottom of the trench shall be dry, continuous, smooth, and free of
rocks and to the line and grade have shown on the drawings.
Ductile Iron Pipe Installation
Before commencing to place any side fill material, any leveling pegs or temporary supports shall be
removed.
Ductile iron pipes shall be supplied in 6.0 meters. lengths; Cut to the required size using the cutting
machine before lifting.
Lower the pipe into the trench. Don’t remove the lifting device (existing crane or chain hoist) before
the pipe is laid and aligned in the support.
Only remove caps and dummy plugs on-site just before the pipe is laid.
Check the horizontal level of the pipe longitudinally and in the cross direction.
Accurate axial alignment of the mating pipes prior to jointing will be done.
Pipe straightness will be achieved using cotton or nylon thread.
Install appropriate pipe thrust blocks where required. The excavation for thrust blocks shall be
carried out prior to laying the pipes except that a trimming margin of not less than 150 mm shall be
left to be removed by hand excavation. No pressure shall be applied to the thrust blocks until the
concrete has matured for at least seven days.
All activities related to the thrust block shall be performed by the civil contractors. All concrete thrust
blocks shall be cast against undisturbed soil.
All joints shall be kept exposed until satisfactory completion of the hydraulic pressure test.
If trench dewatering is necessary, no pipe installation shall start until the design of the dewatering
system has been approved.
The wrapping operation shall preferably take place where low temperature can be maintained in the
summer heat period so as to avoid the tape degrading due to the high temperature of the coated
pipes.
The maximum time between wrapping of the pipe and installation/ laying into the trench will be as
per project specification and manufacturer recommendation.
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TITLE:
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Page 501 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
Sluice valves, fire hydrants, air, and washout valves shall be installed as per approved manufacturer
recommendations/instructions, approved shop drawings, and project specifications.
All equipment and accessories required for testing shall be calibrated and certified by an approved
third-party agency for its accuracy and shall process valid calibration certification.
C. STEP OF WORKS
The installation operations to be adopted for connecting the DI pipe shall be in accordance with the
project requirements and as per manufacturer recommendations. Installation operations shall be done
by trained DI pipefitters.
The DI materials shall be suitable for use with the range of chemical characteristics of the water and
comply with guidelines suitable for using and storing in the environmental condition and normal
working water temperature at 50 degrees centigrade.
All the potable water DI pipes shall be from approved manufacturers and the engineer’s approval.
All the material shall be stored in accordance with the manufacturer’s storage recommendations.
Prior to installation, the material shall be protected as per general specification for the main laying
contract:
D. PROTECTION OF MATERIALS BEFORE INSTALLATION:
D.1 PIPES
A suitable storage area shall be arranged for the duration of the project and subject to approval.
The pipes shall be stacked neatly on timber battens in parallel method with spigots and sockets laid
to alternative ends and using wooden battens between rows (size and location of battens shall be as
manufacture specification) and the maximum recommended number of layers as manufacture
specification.
D.2 VALVES & FITTINGS
Valves & fittings of any type shall be arranged in a suitable storage area and shall take every care to
prevent damage to valves & fittings and their ancillary equipment. These items must not be in
contact with the ground but shall be placed on timbers or planks and provide adequate wedging
between each fitting in the base layer and at the sides.
Valve headstocks, motor gearing, or indicators shall be adequately labeled for identification stored
carefully in weatherproof premises and be reconnected after the erection of the valves.
Electrical equipment shall be protected from the dampness and the dampproofing seals shall remain
intact until the electrician is ready to connect up the equipment.
Air valves are to be stored under cover, in a vertical position with the top of the valve uppermost.
Under no circumstances are air valves to be stored such that the ball is subjected to sunlight.
Resilient seated sluice valves are to be stored in the same fashion as air valves.
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PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 502 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
D.3 Other Materials
Rubber seatings, gaskets, polyethylene film, wrapping tape, adhesive tape, PVC coated copper pipe,
copper fitting, PVC duct, and other anti-corrosion materials and all other equipment and materials
liable to be adversely affected by the heat and sunlight are all to be stored in end door cool place.
Bolt, nut, the washer should be stored under cover in dry conditions and before used should be
lubricated.
All material like rubber seating, gaskets, adhesive tape, wrapping tape, and other anti-corrosion
materials shall be stored indoors and in an air-conditioned space prior to starting installation.
All the interfacing of tie-in points with other packages shall be done according to project specification
and shall be as per approved shop drawings with coordination with Engineer’s representative.
Corrosion protection shall be applied to the ductile Iron pipes, clean the surface from dust then apply
the primer to the pipe surface and wrap the pipe with approved color self-adhesive wrapping tape.
D.4 CORROSION PROTECTION
All buried pipes and related fittings shall be protected from corrosion by the application of a PVC /
bituminous corrosion protection tape and sleeving.
All pipes and fittings shall have the appropriate external corrosion protection.
D.5 WRAPPING OF PIPE BARREL
The entire external surface of the pipe shall be clean, dry, and free from all rust, dust, grease, or any
other deleterious matter.
Only touch up shall be done at the site.
No grit blasting or sandblasting shall be done at the site.
The clean, dry, primed prepared pipe surface is to be machine wrapped with the approved tape.
The tape is to be applied spirally with a minimum of 25 mm overlap for the normal area and 55%
overlap for the waterlogged area using sufficient tension to ensure the tape conforms and adheres to
the pipe surface. End laps between successive rolls to be a minimum of 200 mm. The wrapping shall
extend as close to each end of the pipe as practicable, so the pipe can be jointed in the trench
damage to the wrapping.
After the pipes are jointed the step between the spigot and socket area is to be shaped up with the
tape manufacturer’s to give a smooth surface profile for wrapping. The joints shall then be wrapped
as described above and the joint wrap to extend a minimum
150 mm onto the existing wrap on either side of the joint. Any transit damage to the wrapping tape
will be repaired before the pipe is wrapped in the sleeve and laid in the trench.
D.6 WRAPPING OF BURIED FLANGES, VALVES, AND OTHER FITTINGS
Buried flanges, valves, and fittings shall be protected by approved PVC / bituminous protection
wrapping tape, plus primer and putty supplied by the tape manufacturer.
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
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TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 503 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
All exposed metal surfaces of the object to be protected and existing protective coating at each
extremely to be cleaned free of all rust, weld spatter, mill scale, dirt, dust, lime wash, and other
deleterious matter.
The clean, dry, prepared surface is to be brush primed with one thin continuous coat of quick-drying
primer and allowed to dry completely.
All pipe and fittings shall be wrapped with an approved polyethylene sleeve if required by project
specification.
The polyethylene film will be supplied in tubular form and it is to be placed around the barrel of the
pipe or fittings and fixed with sufficient overlaps as required and taped with an approved tape of a
minimum of 50 mm width.
All such sleeving is to be done before the pipes and fittings are lowered into the trench.
After the pipes and fittings have been lowered into the trench and jointed, the polyethylene film shall
be folded over the joints with an overlap of 300 mm.
D.7 Polyethylene Sleeving
All pipes and fittings shall be wrapped with an approved polyethylene sleeve if required by the
specification. The polyethylene film will be supplied in tubular form and it is to be placed around the
barrel of the pipes or fittings and fixed with sufficient overlaps and taped with an approved tape of
the minimum width of 50mm.
All such sleeving is to be done before the pipes and fittings are lowered into the trench.
After the pipes and fittings have been lowered into the trench and jointed, the polyethylene film shall
be folded over the joints with an overlap as directed by the consultant.
The contractor is to ensure that the fold is positioned such that it is on the crown up the pipe. The
contractor is to ensure that there is a continuous film of polyethylene between pipes and fittings and
the surrounding backfill material. No backfilling of the pipe is to take place until it has been checked
and passed the integrity of the polyethylene protection.
Before the pipes are laid, they are to be carefully brushed before the pipes through to remove any
soil, stones, or other matter, which has entered.
After the trench has been excavated and required elevation achieved, obtaining approval to proceed
with granular bedding and compacted as per project specification for the main laying as follow: (Will
be done by civil contractor)
i. Imported granular material shall comprise crushed clean hard limestone. The crushed limestone
shall be obtained from an approved source.
ii. Granular material shall contain no excessive quantities of dust, soft or flaky particles, shells
congealed lumps, nodules of soft clay, shell, alkali, or other contamination likely to affect adversely
the compaction of the material or to cause damage to pipes.
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iii. Prior to commencement and during the progress of works the contractor shall provide samples of
the proposed granular material to be used in the works. This sample will be retained for comparison
with deliveries to the site during the works.
iv. The grading of fine aggregate, when determined by the method described in BS 812 (British
Standard 812), shall lie within the respective limits specified.
Ensure that pipes and fittings to be joined are of the same nominal size, pressure, and type, making
sure that no stones or sharp ends in bedding.
Special attention needs to be given to the bedding, side filling and backfilling of the trench. This
provides the necessary support for the pipes.
The pipes shall be laid according to coordinates and elevations specified in the approved drawing.
The tolerances for elevation shall be strictly followed.
Before the pipes are socketed the joint shall be carefully cleaned and dried. No dirt or water is to be
allowed to enter before the joint is made. No packing of any kind shall be used to locate the pipes in
position in the trench.
All precautions shall be taken to avoid any foreign material from entering the pipe during installation.
Ensure no debris, tools, clothing, or other materials shall be left inside the pipe.
Pipe installation shall start at low points towards high points.
Pipes will be lowered in the trench and installed/jointed in the specified slope, level, and coordinates
as per the approved shop drawings, seal the open ends of the pipes with caps after completion of
activities according to project specification of laying contracts.
D.8 SEALING ENDS OF PIPES
Immediately after laying, the open ends of the pipes shall be sealed with unperforated wooden plugs
of appropriate size or approved expanding stoppers to prevent the entry of extraneous matter or
water which might contaminate or damage or affect the working of the system.
These plugs are not to be removed until the end in question is no longer classified as an open end.
Pipes, valves, fittings, and other materials shall be handled, moved, lifted, or lowered, connected
with the least possible impact, and handling equipment using slings with a third-party inspection
certificate.
Valves (washout, air release, etc.) and all fittings (tees, bends, reducer, etc.) and other related
materials (fire hydrants) shall be fixed according to manufacturer recommendation, specification,
and approved shop drawings.
All pipes, valves, fittings, and their ancillary equipment shall be protected before and after erection
against the collapse of earthworks, falls of materials, concrete and cement droppings, wood, and
other shavings, and all deleterious material.
When setting and assembling flange work, care shall be taken to ensure that the flanges and bolts
are correctly positioned and bolts are evenly tightened up in the correct sequence.
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Immediately after laying, open ends of the pipes shall be sealed with imperforated wooden plugs or
approved expanding stoppers to prevent the entry of extraneous matter or water which might
contaminate or damage and affect the working on the system.
At curves on the pipelines; horizontal, vertical, or a combination of both bends and elsewhere shall
be provided with the thrust blocks, supports blocks, etc. as per approved detailed shop drawings and
requirements.
As-built surveying shall be taken and recorded prior to surrounding, the pipe surround shall not be
less than 250 mm above pipe crown.
Backfilling of the trench, after obtaining approval from the Engineer shall proceed immediately after
satisfactory completing of work. No backfill layer shall be covered by the next layer of construction
until it has been inspected, tested, and approved by the Engineer.
Approved PVC marker tape shall be laid directly above the water main, 300 mm below finished
ground level, and 200 mm below the service connection line. Under carriageways, marker tape shall
be laid on top of the concrete protection to the water main or as directed by the Engineer.
The remaining depth of trench above sand layers can be backfilled with approved excavated material
in layers of not less than 200 mm compacted thickness, each layer will be compacted by roller or
plate compactor. The final layer will be tested to 95% proctor.
For the scenarios for pipe crossing new road work and other utilities.
10. LAYING, JOINTING PIPES AND FITTINGS
Pipes and special castings will have flange joints, couplings, bolted glands, joints, or similar. Before
the pipes are laid they are to be carefully brushed before the pipes through to remove any soil,
stones, or other matter, which has entered.
Pipe laying shall commence at low points, i.e., washout branches, and proceed towards summits, i.e.,
air valve location. Pipes are to be lowered singly into the trench brought to proper inclination, firmly
bedded, and made to rest throughout their whole length as specified.
Before the pipes are socketed the joint shall be carefully cleaned and dried. No dirt or water is to be
allowed to enter before the joint is made. No packing of any kind shall be used to locate the pipes in
position in the trench.
Pipes, valves, fittings, and other materials shall be handled, moved, lifted, or lowered, connected
with the least possible impact, and handling equipment using slings made of terylene, nylon, or other
suitable synthetic fibers capable of withstanding the required loads.
10.1 JOINTS
When setting and assembling flange work care shall be taken to ensure that the flanges are correctly
positioned as required that the component parts of the joints are clean and dry that the faces and
bolt holes are brought firmly together that the bolts are evenly tightened up in the correct sequence
and that the protection of the flanges is made good.
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 506 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
All jointing out strictly in accordance with the manufacturer’s instructions and prior to jointing a
demonstration may be given by the manufacturer’s supplied skilled pipe jointer/representative or a
trained pipe jointer of the contractor.
10.2 FLEXIBLE MECHANICAL JOINTS
The spigots and sockets of all types of flexible jointed pipes shall be thoroughly cleaned before
jointing rings are placed and jointing completed.
Notwithstanding any flexibility provided in the pipe joints, pipes must be securely positioned to
prevent movement during and after the making of the joints and no person shall be employed on the
jointing of pipes who is not thoroughly experienced and skilled in the particular work in hand.
No deviation from a straight line will be allowed without approval. Any such deviation shall be
provided with thrust blocks if so instructed.
10.3 CUTTING PIPES
Pipes shall be cut by a method, which provides a clean square cut of pipe and lining and then
chamfered where required without being shattered or separated.
All cut or trimmed ends and the parts of any pipe on which the coating may have suffered damage
shall be re-coated as per manufacture specification.
10.4 COLLARS AND CLOSERS
Where loose collars are used to join pipes cut for closers special tools shall be employed to keep the
inside of the pipes flush and the collars concentric with the pipes while the joint is being made.
11.SLUICE VALVES AND FIRE HYDRANTS
11.1 FACES AND SEATING
Gunmetal faces and seatings of all sluice valves shall be kept clean and free of dirt. No valve shall be
laid and operated without first wiping the gunmetal faces with a clean cloth dipped in clean non-
mineral oil.
After such cleaning, every care is to be taken to ensure that no extraneous matter enters the valve
during the laying process.
The gate groove in the base of the valve is to be thoroughly cleaned by hand before laying the valve.
Should bitumen, cement, or any other matter be deposited on the gunmetal faces or seatings it shall
be dissolved using proprietary solvents or carefully removed by methods that do not involve scraping
the gunmetal faces.
11.2 OILING OF EQUIPMENT
Before any sluice valve or hydrant is commissioned, all gears, bearings, and spindles should be oiled
with approved oil as recommended by the valve manufacturer. Oil baths are topped up to the
appropriate levels and all grease nipples are charged with the grease of the approved manufacturer.
11.3 STUFFING BOXES
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Every stuffing box shall be examined when the main is under pressure test and leaking boxes shall be
adjusted or repacked with square plaited lubricated packing, or ‘O’ rings of approved manufacture.
The stuffing box shall not be so tightly adjusted or packed as to materially affect the friction of the
packing on the spindle.
11.4 AIR VALVES
Air valves shall be checked before the main is tested to ensure that the balls and faces are not
damaged and that there is no dirt or other deleterious material in the cavities of the body.
All air nozzles shall be probed to see that they are clean. Air relief valve assemblies shall not be
installed directly to any storm drain or sanitary sewers system.
11.5 CONNECTIONS TO EXISTING LIVE WATER MAINS
Where no tee has been left for future development, the connection shall be made using an approved
cutter or under pressure drilling tee and drilling machine.
The pipe where is to be fitted will be clean, dry, and free from all rust, dust, grease, wrapping tape, or
any other deleterious matter and shall be painted with the quick-drying primer. After fitting and
drilling the whole tee shall be protected as per specifications.
11.6 PROTECTION OF EQUIPMENT DURING LAYING
All pipes, valves, fittings, and their ancillary equipment shall be protected before and after erection
against the collapse of earthworks, falls of materials, concrete and cement droppings, wood and
other shavings, and all deleterious material.
11.7 SEALING ENDS OF PIPES
Immediately after laying, the open ends of the pipes shall be sealed with unperforated wooden plugs
of appropriate size or approved expanding stoppers to prevent the entry of extraneous matter or
water which might contaminate or damage or affect the working of the system. These plugs are not
to be removed until the end in question is no longer classified as an open end.
11.8 ANCHOR BLOCKS, THRUST BLOCKS, SUPPORT BLOCKS, ETC.
At curves on the pipelines, either horizontal, vertical, or a combination of both bends or elsewhere,
the pipes must have thrust blocks of concrete Grade SRC 20 to the dimensions shown on the
drawing.
Concrete work shall be done by civil discipline.
Thrust blocks shall be cast against un-disturbed soil and shall be cast at all socketed bends, tees, and
tapers/ reducers.
11.9 SERVICE CONNECTIONS
This specification covers the laying of MDPE pipes with associated fittings for the size range 20 mm
(1/2”) up to 63 mm (2”) underground and aboveground.
12.EXCAVATION & BACKFILLING
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Excavation and backfilling for MDPE service connection will be in accordance with general
specifications for main laying contracts noting that pipe depth shall be 600 mm as detailed in the
specifications of the project.
MDPE service pipe shall have 100 mm sand bedding, 150 mm selected backfill material with 100%
compaction, and backfill material of varied depth up to ground level, all in accordance with road depth
highways maintenance section requirements.
The minimum width of trench excavation is to be service pipe duct diameter (either 100 mm or 150
mm) used plus 200 mm and the maximum width of trench excavation is to be service pipe duct
diameter used plus 300 mm.
13.MATERIALS
All materials supplied shall conform to the project specification for materials used in pipe-laying
construction and service connection work.
Service connection size
Diameter of Main Maximum Size of Connection with Saddle
80mm 20mm
100mm 25mm
150mm 32mm
200mm 40mm
300mm 50mm
The sizes of service connections will differ, in no circumstances shall the sizes of the connection exceed
the following values:
14.MDPE PIPES AND FITTINGS INSTALLATION INSTRUCTIONS
Trench marker tape with an aluminum strip in the middle shall be laid at a minimum 450 mm depth
below ground level along the route of pipe.
The contractor shall tap the distribution main at depth of a minimum of 900 mm and bring MDPE pipe
from ferrule to a higher elevation without the use of any fittings, as far as possible, so that MDPE the
pipe could be laid at a minimum depth of 600 mm from ground level, from the distribution main till it
reaches customer boundary wall.
When laid above ground along with customer wall premises or elsewhere, polyethylene pipe shall be
protected with GRP duct of minimum thickness 3 mm.
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Two sizes are allowed; 2” duct for 20mm (1l2”), 25mm (3/4”), 32mm (1”) & 40mm (1 ¼”) and 3” duct
for 50mm (1 ½”) & 63mm (2”).
The GRP duct shall start from ground level and be extended to an appropriate height to secure the
exposed MDPE pipe near the water meter service cabinet. The GRP duct shall be of a semi-circular
shape and be firmly fixed to the wall with brackets.
15.HYDRAULIC TESTING
The pipelines are to be subjected to the following hydraulic tests:
Test to a pressure of one and half time the working pressure or to a pressure of 9 bars which is the
greater and is to be carried out on the section of main during laying.
After completion of all sections of similar diameter, a test shall be carried out at the specified pressure
on the completed pipeline.
After completion of service connection, a test of 6 bars shall be carried out on the completed pipeline.
The first test is to be to a pressure of 9 bars and is to be carried out on sections of the main during
laying. The second test (final) is to be 6 bars, carried out on the competed pipeline, and is designed to
test the service connections. However, in case no service connections are installed, the second test
(final test) shall be 9 bars, not 6 bars.
In general, testing should not be carried out against closed valves, the final 9-bar test can be carried
out in sections against closed valves.
15.1 INITIAL TEST
This test will be carried out on a short section of the main, maximum length to be 1.5 km with joints
left exposed, with in-service connections installed, and against proper stop-ends. Under no
circumstances this test be carried out against closed valves.
Each section of the pipeline is to be tested to a specified pressure, such pressure being recorded at
the lowest point on the test section.
The contractor is to supply all necessary pumps, water, approved blank suitably drilled and tapped
for use as the temporary test ends, small bore pipework to fill the main supplying the test hand,
pressure gauges, isolating cocks, measuring vessels for measuring the quantity of water lost during
the test period and all other materials necessary to ensure successfully testing of the section.
15.2 FINAL TESTING
This test will be carried out when the pipeline has been fully completed i.e., all service connections
made fully backfilled and reinstated, all valve chambers complete, etc.
The pipeline is to be tested to a specified pressure, such pressure being recorded at the lowest point
on the test section.
15.3 TESTING METHOD
Where pipes are being tested by sections, each section must be properly sealed off with a stop and
securely anchored to prevent any movement. Unless otherwise specified, the maximum thrust on
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the stop ends for the 9 bar test shall be as per project specification for the main laying as shown
below.
Pipe Diameter mm Thrust Tons
100 0.7
200 2.8
300 6.4
400 11.3
600 25.3
900 57.2
1200 101.7
If the anchor is to be made of concrete, testing must not start until the concrete has developed
adequate strength.
After the contractor is satisfied that all stop-ends are adequately anchored, the section under test is
to be filled with water taking care that all air is displaced either through vents at the high points or by
using a swab.
After filling the pipeline, must be left under operating pressure for a period to permit the lining to
absorb water, pipeline movements, the release of any air still remaining in the section, etc.
The test will last for a period of 24 hours after which time the pressure will be noted and the seals
removed.
If a drop in pressure occurs, the quantity of water added in order to re-establish the test pressure
should be carefully measured. Unless otherwise specified this quantity should not exceed 0.1 liters
per millimeter of pipe diameter per kilometer of pipeline 24 hours for each 30m head of pressure
applied.
The requirements per kilometer per day shall be as per project specification for main laying contracts
or project specification and as shown below.
15.4 BAR TEST QUANTITY OF WATER
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Pipe Diameter (mm) Litres/km/24 hours
100 30
150 45
200 60
300 90
400 120
600 180
1200 360
15.5 BARTEST QUANTITY OF WATER
Pipe Diameter (mm) Litres/km/24 hours
100 20
150 30
200 40
300 60
400 80
600 120
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900 180
1200 240
If the test is not satisfactory i.e., the amount of water to be pumped in to bring the pressure back to
the test pressure is greater than the quantities given in the tables above, the fault is to be found and
rectified.
Where there is difficulty in locating faults, the section under test, where it is in the initial test should
be sub-divided and each part tested separately. For the final test, such sub-division can be done by
closing valves. All fittings and other materials required for re-testing are the responsibility of the
contractor.
If no faults can be found, then one of the following methods can be utilized to find the leak:
1. Visual inspection of each point not backfilled.
2. Use of a bar probe to detect signs of water in the vicinity of backfilled joints.
3. Aural inspection using a stethoscope or listening stick in contact with the pipeline.
4. Use of an electronic listening device, which detects and amplifies the sound of any escaping fluid.
5. Injection of dye into the test water (only of use in the waterlogged ground).
6. Introduction of nitrous oxide into the test water and using an infra-red gas concentration indicator
to detect the pressure of any nitrous oxide that has escaped through the leak.
All pressure tests on mains will be done using water pressure tests and under no circumstances will
pneumatic testing be permitted.
16.SWABBING AND STERILIZATION
Before the final commissioning of the pipeline, the contractor shall swab and scour the pipeline to
ensure that this is free from obstructions, debris, and sediment.
16.1 SWABBING
One of the following methods shall be used to swab the pipeline.
Hydraulic swabbing
A foam plastic cylinder swab shall be inserted into the pipeline and driven by hydraulic pressure
through the pipeline. The dimensions of the swab shall be as follows:
a. Pipe diameter less than 300 m
Swab diameter = 1.25 x pipe diameter
Swab length = 2 x diameter
b. Pipe diameter greater than 300 m
Swab diameter = pipe diameter + 75 mm
Swab length = 1.5 x diameter
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The pipe shall be swabbed in one length or in a series of sections. Should the swab jam at any point,
it will be the contractor’s responsibility to either dislodge the swab or to locate it and remove a
section of pipeline adjacent to facilitate the removal of both the swab and the blockage. Swabbing
will be continued until such time as all obstructions are removed and swab freely through the main.
16.2 DRY SWABBING
A form plastic cylinder swab shall be inserted into the pipeline at the beginning of pipe laying and
pulled through each pipe as it is laid by means of the rope, thus providing an effective dry swab.
To avoid contamination and infestation, an expandable plug shall be fitted at the end of the pipe at
each break in the working day and when pipe laying is suspended. The swab shall be replaced at
regular intervals to ensure a tight all-around fit.
16.3 SCOURING
After the pipeline has been successfully swabbed, the pipeline is to be flushed with clean water. The
scouring shall be continued until the water runs clear and the contractor shall ensure that no erosion
or silting occurs in the watercourses or drains into which the water is discharged.
16.4 STERILIZATION OF WATER MAINS
After the mains have been tested and approved, swabbed, and flushed out, the mains shall be slowly
filled with clean water containing a chlorine solution injected.
In general hypochlorite solution will be added to the water passing into the main such that the
measured chlorine residual is 20 mg/l (ppm). After all the mains to be sterilized have been filled, the
mains shall be left full of chlorinated water for a period of 24 hours.
After the period the main is to be emptied, filled with clean water, and left for a further period of 24
hours. Then the biological test is to be carried out and the sample shall be taken from the front
points of the main as measured from the level of chlorine residual.
If the tests fail, the procedure is repeated until satisfactory results are achieved.
17. QUALITY ASSURANCE AND QUALITY CONTROL
17.A. QUALITY ASSURANCE REQUIREMENTS
The contractor shall provide the required documents for the consultant’s approval prior to initiating
the execution of this activity as per project specification.
The Quality Control requirement shall include related ITPs and other related documents as
applicable.
Refer to Inspection Test Plan.
17.B. QUALITY ASSURANCE PROCESS
The contractor shall notify the Engineer 24 hours in advance prior to the start of activity and
comments from the Site Instruction will be complied with the satisfaction of the consultant.
The contractor shall consult the public utility authorities not less than one month before it is
proposed to commence work to ascertain whether any underground installations will be affected by
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the proposed work, in which event the contractor shall make all necessary arrangements with the
public utility authorities to safeguard the installation.
17.C. FOLLOW UP AND EVALUATION
Follow-up on quality performance shall be carried out through an in-house monitoring system such
as progress reporting to the planning department, daily, weekly, and monthly reports generated by
the planning department to closely monitor site performance.
All the above shall be conducted in close coordination with the quality department to monitor any
deviations from the Quality Management System requirement and induce corrective actions
whenever required to eliminate non-conformance or quality deviations.
17.D. RECORDS
Checklists (CKL)
Inspection Request (INR)
Inspection and Test Record (ITR)
18. ATTACHMENTS-Method Statement of Potable Water/Firewater Network Installation and Testing
Appendices
Appendix A: HSE Risk Assessment for Installation and Testing of Potable/Firewater Network
Appendix B: Inspection and Test Plan Installation and Testing of Potable/Firewater Network
Appendix C: Checklist for Installation and Testing of Potable/Firewater Network
Appendix D: Ductile Iron Piping Leak Test
Appendix E: Ductile Iron Pipe Disinfection Checklist
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METHOD STATEMENT OF
LV CABLES AND
WIRES INSTALLATION
SR. EFFECTIVE REV. MSS MANAGER MSS PROJECT CLIENT
CLIENT QA/QC
NO. DATE NO. QA/QC MANAGER SUPERVISOR
LV CABLES AND WIRES INSTALLATION
1. SCOPE
The method statement of LV power cables and wires installations describes the procedures as per
applicable standards, codes, and project specifications. The scope of this method statement involves
the low voltage (≥25V – <1kV) power cable and wires laying activities.
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2. ABBREVIATIONS/DEFINITIONS
IFC Issued for Construction
WIR Work Inspection Request
ITP Site Inspection and Test Plan
HSE Health, Safety and Environment
PPE Personal Protective Equipment
RA Risk Assessment
MIR Material Inspection Request
MS Method Statement
QA/QC Quality Assurance/Quality Control
PQP Project Quality Plan
LV Low Voltage (415 V)
MEP Mechanical, Electrical & Plumbing
3. SEQUENCE OF WORKS
The following are the systematic procedure for the installation of LV cables & wires prior to
installation, it will be ensured that:
All relevant documentation such as approved shop drawings, checklist, approved method statements,
material, etc. applicable to a particular section of work will be checked by the site engineer prior to the
commencement of work ensuring that these are of the correct type as reviewed by the engineer.
Before commencement of installation, material inspection will be carried out prior to being withdrawn
from the storage area i.e. quantity, physical damage and brand/make. Before the beginning of the
installation, it will be ensured that the approved valid Permit To Work (PTW) is available on site.
The engineer in charge will ensure that approval and standard tools and tackles are available to carry
out the work.
Safe access to work areas will be provided and will be approved by the competent safety person prior
to commencement of works if applicable.
Check the work area tidy and remove flammable materials if any and a safe environment will be
ensured.
Where the Risk Assessment identifies high-risk works a permit to work will be obtained from the safety
department.
Competent manpower will be employed to carry out the installation work.
Prior to installation, it will be ensured that all the civil works are completed. Necessary civil clearance
will be obtained (if applicable) prior to the start of installation.
4. MATERIAL TRANSPORT
The material supplied will be packed for protection against damage during handling, transporting,
warehousing, and installing.
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All the related Low Voltage Electrical Distribution Systems and other related accessories will be
handled and transported and unloaded at the site strictly as per manufacturers’ instruction.
After delivery, items will be inspected for any transport both internal and external components casing
damage, in compliance with project specification & materials submittal.
Approved shop drawings will be posted at the workplace for site reference used and installation works.
5. DELIVERY AND STORAGE
Materials will be delivered, storage and equipment handling will be stored as directed in a neat with
safety precautionary measures according to the manufacturer’s recommendation and in accordance
with the HSE Plan.
Deliveries will be Inspected and handled at the site area according to the given instructed
requirements.
Mechanical handling will be considered prior to manual handling
When materials arrive at the site will be inspected randomly and will ensure that the materials are as
per approved material submittals.
Any discrepancies, damage, etc. found to the materials will be notified and reported to QA/QC
Engineer and Project Engineer for further action.
All the material will be Inspected and approved by the engineer prior to dispatch to the site and
commencement of works.
Materials found not suitable for site use will be removed from the site immediately.
While unloading, shifting, and storage, it will be ensured that there are no damages.
All delivered materials will be inspected on arrival at the site.
All materials will be free from any defects or damages and foreign materials that will result in the
inability to install the materials and subsequent deterioration.
6. HANDLING
Carefully transport the LV cables & wires to the installation location by means of boom-truck or forklift
considering the location of installation.
Forklift and/or equipment to be used for handling the cables & wires will be inspected and will be in
good condition.
Delivered materials will be covered with polyethylene sheets while storage to ensure free from dirt
and dust.
When off-loading, materials will be lowered and not dropped to the ground.
All materials delivered on-site will have relevant supporting documents complying with the
specification of the project.
All incoming panels will be off-loaded by boom truck or manually into the storage area.
Visually inspect the panels for physical damage.
All the materials will be as per approved material.
No materials will be permitted to enter the work location without prior inspection and approval.
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Material Inspection Request (MIR) will be issued and will be inspected by the engineer and approved
prior to dispatch to the site and commencement of works.
7. SITE PLANNING & PREPARATION
Before the commencement of installation, the following are required to be carried out.
No one will be allowed to interfere with installation work ongoing, or work in the immediate vicinity of
installation without a valid permit to work signed by the QA/QC Engineer. This applies to both
temporary and permanent electrical installations and equipment. It is to be done to avoid any damage
to Electrical cables and wires.
Before the installation of cables and wires, a work permit needs to be obtained and it will be ensured
that other MEP services are already installed in the particular section.
It will be ensured that the cable containment system for both Normal and Emergency power supply is
installed and inspected.
Prior to starting the installation, it will be ensured that the latest approved shop drawings/ MEP
services coordination drawings related to the installation area are referred and the required materials
are available at the site as per approved material (cables and wires).
Prior to starting the installation, it will be ensured that the latest approved shop drawings / MEP
services coordination drawings related to the installation area are referred and the required materials
are available at the site as per approved material (cables and wires).
Check that ladder/trays are free from any sharp edges and have sufficient space for installing the
cables.
20 % spare capacity will be maintained once all cables have been installed on trays.
Trays will not be smaller than the minimum size stated on the drawings or specified later and will be so
sized; if not specified, then it will be ensured that the calculated size is large enough for the
requirements and provide 20% spare capacity for future use.
For spaces between the cables, while installing, the details mentioned in the approved shop drawing
will be followed.
8. METHODOLOGY
8.1 WIRE INSTALLATION
The sub-circuit and final circuit wiring for lighting, small power, and equipment power installation
(wire size in mm2) will be accordingly to the schedule provided in the approved shop drawing.
Make sure that all conduits and boxes on both ends are free from damages and blockages etc. and
installation is approved.
For longer wire pulling, approved wire pulling lubricant will be used in conduit to avoid
damage/stress on the wire (if required).
The blockage will be checked by inserting the draw wire and checking that it reaches other ends
without any disturbance.
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 519 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
Once the conduit is not blocked the wires will be pulled using the draw wires while ensuring no
damage occurs while pulling.
While pulling the wires, care will be taken to not insert the pull tension greater than the
manufacturer’s allowed limits.
Refer to the below table for pulling tension and bending radius:
Table1: Maximum Pulling Strength & Bending Radius details (approximate) of cables
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Approximate
Approximate Bending Radius
Cable Size Cable Type Maximum Pulling
(mm)
Strength (KN)
2*4 mm2 CU/SWA/XLPE/SWA/HFFR 0.4 161
2*6 mm2 CU/SWA/XLPE/SWA/HFFR 0.6 178
3*4 mm2 CU/SWA/XLPE/SWA/HFFR 0.6 173
3*10 mm2 CU/SWA/XLPE/SWA/HFFR 1.5 215
3*150 mm2 CU/SWA/XLPE/SWA/HFFR 22.5 526
3*300 mm2 CU/SWA/XLPE/SWA/HFFR 45 694
4*4 mm2 CU/SWA/XLPE/SWA/HFFR 0.8 185
4*6 mm2 CU/SWA/XLPE/SWA/HFFR 1.2 211
4*10 mm2 CU/SWA/XLPE/SWA/HFFR 2 232
4*16 mm2 CU/SWA/XLPE/SWA/HFFR 3.2 260
4*25 mm2 CU/SWA/XLPE/SWA/HFFR 5 320
4*35 mm2 CU/SWA/XLPE/SWA/HFFR 7 353
4*50 mm2 CU/SWA/XLPE/SWA/HFFR 10 356
4*70 mm2 CU/SWA/XLPE/SWA/HFFR 14 420
4*95 mm2 CU/SWA/XLPE/SWA/HFFR 19 464
4*120 mm2 CU/SWA/XLPE/SWA/HFFR 24 522
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4*150 mm2 CU/SWA/XLPE/SWA/HFFR 30 569
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4*185 mm2 CU/SWA/XLPE/SWA/HFFR
steps steps 37 628
Step Process
2
4*240 mm CU/SWA/XLPE/SWA/HFFR 48 698
Property of MSS – Approved (Controlled document in Document Repository)
4*300 mm2 CU/SWA/XLPE/SWA/HFFR 60 779
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Use the rolling wire drum axle to pull the cable stress-free.
8.2 LV CABLE INSTALLATION
As per the drum schedule and at the location where space is available for working, the drum will be
placed on a jack and spindle arrangement to ensure free rotation of the drum.
Erect scaffolding where required as per the site requirement.
The cable will be pulled by using pulling means such as rope, cable pulling socks, and a winch
machine so as not be damage the cable or its containment system.
Cable roller will be placed under the cable during pulling over long distance and standoff roller for
acute bands, to ensure that the cables are pulled with minimum effort and the cable outer jacket is
free of scouring lines.
Do not allow the cable to twist or rotate about its longitudinal axis.
Install cables to allow anyone cable to be subsequently removed without disturbing the remainder.
Damage cables will be removed unless the engineer agrees to a repair. Protection of cables against
possible mechanical damage will be provided wherever seen to be necessary by the engineer. All
cables are to be run with particular regard to neatness. Multiple runs are to be arranged so that
cables entering or leaving the run do so in a logical order.
Cable pulling lubrications can be used where it is difficult to pull the cable or otherwise advised by
the Supervisor Engineer. Make sure the lubricant will not deteriorate the cable insulation.
It will be ensured that the correct set and type of reel roller are used for cable pulling.
The cable will be free of any static load i.e. to be placed side by side parallel on the cable tray or
ladders. Any kind of dead weight on the cable will be avoided.
At all-time, the cable schedule & section drawings for the relevant area will be referred to ensure
proper location on cable on the required ladder/tray and to ensure compliance with project
specifications.
The cable will be secured to the containment system using approved cable tie/cable cleats for
horizontal and vertical runs. The minimum distance between the cable tie will be 0.5m but the details
available on the approved shop drawing will be followed.
At all-time of pulling, mark both power and earth cables for pairing them on both sides of the
connection i.e. at sending and receiving ends.
Before termination complete length and route of the cable will be inspected by supervising engineer.
Termination will be done by using the approved termination materials that include glands, lugs, and
other accessories part of the termination kit, by using proper crimping tools.
8.3 WIRE PULLING IN CABLE TRUNK
Following steps will be adopted for pulling wires in the trucking:
Make sure that the cable trunk is inspected for the wire pulling system.
Make sure that all trunk and terminal boxes on both ends are free from damages and blockages.
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Once trunking is checked the wires will be pulled using the draw wires while ensuring no damage
occurred while pulling.
While pulling the wires care will be taken to not insert the pull tension greater than the
manufacturer’s allowed limits.
Erect scaffolding where required as per the site requirements.
At acute bends to ensure that the cable is pulled with minimum effort, pull manually by using the
safely erected scaffolding.
Before termination complete length and route of the wiring will be inspected by QA/QC Engineer.
A separate method statement has been submitted for the installation of the cable tray/ladder.
Before pulling the cable through the tray/ladder, the WIR for the installation of the tray/ladder needs
to be approved.
Set up cable stand correctly for even feeding of cable. Each stand will be in line with the other. Avoid
the angle at which the cable will be fed from the reel to the tray.
Cable size and routing are as per the approved drawing and the maximum allowable cables in a tray
need to be as per the approved drawing.
Use cable roller for cable pull from start to endpoints. Rollers will be placed at every 3 meters (or as
close as needed) for the entire length of pull.
Install corner-type roller at every corner or bend.
Manually lay the rope above the tray until it reaches the starting point of cable pulling. The rope will
be above the rollers.
An approved pulling compound will be used for pulling the cable.
Cable pulling tension will be followed as per the manufacturer’s recommendation.
Manually feed the cable to the tray at the starting point and pull the rope without unreeling cable on
the drum to develop certain pressure between cable and cable stocking until it fully grips the cable.
After checking the grip and everything is satisfactory, the Site Engineer can give the order to start
pulling the cable to the workers assigned at the rope side.
All workers assigned at cable reel location will manually roll drum and unreel cable.
During the entire pull, only the person in charge i.e. Supervisor or Foreman will give commands to
workers pulling the cable in order to synchronize with the workers releasing cables at the drum end.
The assigned guider will check cable condition at every cable tray corner or offset location.
After the cable has reached the other end, measure the exact length required for termination to the
equipment/panel board. Provide enough allowance (slack) for every termination point before cutting
the cable at the drum end.
Measure the required length of cable at drum end to terminating point and unreel it from the drum.
Provide adequate slack also for termination.
Identify cable at both ends for proper identification of cable. The marker sign will be the same as the
feeder designation in the cable schedule.
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Coil the cable at each end until termination to equipment/panel board has started.
9. CABLE JOINTS
Joint in LV cable will only carry out prior approval from the consultant as per the project specification.
Accessories for jointing the cables will be selected accordingly to the approved material.
Check if the appropriate color of the wires has been used from the source to the destination.
Jointing of different colors of wires will not be allowed under any circumstances.
QC inspection will be done after each jointing a continuity and insulation will be conducted.
10.IDENTIFICATION CABLES AND WIRES
Temporary identification labels and notices will be provided immediately after the installation
inspection isapproved.
Warning, caution, and instruction notices where indicated in the drawings will be provided
temporarily.
It will be ensured that all identification labels and notices are installed in a visible position.
When cable fixing and termination is completed then Permanent label and notices will be provided
accordingly.
11.TOOLS / EQUIPMENT
Measurement tools
Electrical Tool Box
Marker / whitener & line marker
Lugs punch
Cable drum jack
Normal and Right-Angle Cable rollers
Steel pulling wire
Identification tags
Folk Lift
Spanners set
Heat Gun
Cable/wire lubricant (if required)
Multimeter / megger meter
Mobile scaffoldings
Cable winch machine (if Required)
Flags & signboard
Hydraulic Cable Cutter
Hacksaw
Hand shovel
Dynamometer
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12.MATERIALS
UPVC duct and fittings
Cable tray/ladder
All types and sizes of low voltage cables as per approved shop drawings
Cable end caps
Warning tape
Cable cleat
Cable joint kit
Cable support
Quality Control for Method Statement of LV Cables and Wires Installations
The Inspection and Test Plan (ITP) for this method statement summarizes various characteristics to be
checked. The concerned Site Engineer or Site Supervisor will be responsible in ensuring compliance for
this operation.
The site QA/QC Engineer will carry out quality control checks and report the inspection results.
13.QUALITY RECORDS
Quality records will be provided as identified in the ITP and maintained as per ISO 9001/2015, standard
form of records, quality checklists and QA/QC reports requirements.
The submission of as-built records will be done after completion.
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METHOD STATEMENT FOR
SMDB, DB & FEEDER PILLAR
INSTALLATION AND TESTING
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NAME:
SR. EFFECTIVE REV. MSS MANAGER MSS PROJECT CLIENT
CLIENT QA/QC
NO. DATE NO. QA/QC MANAGER SUPERVISOR
SMDB, DB & FEEDER PILLAR INSTALLATION AND TESTING
1. SCOPE
This method statement shall ensure that the installation is executed safely. This method statement
aims to ensure that quality assurance and quality control activities are adopted by the contractor for
the project so that the job execution complies with the requirements and serves the intended function
to a satisfactory level.
2. REFERENCES
This method statement is subject to the requirements as stated in the following regulatory & statutory
documents, applicable standards/specifications/building codes:
Project Specification
Relevant Sections of IEC/BS.
Project approved materials/shop drawings/IFC drawings
Approved Project HSE Plan
Approved Project Emergency Response Plan
Approved Project Waste Management Plan
Occupational Health and Safety
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3. ACCESS/EGRESS
Works will be started or carried out only when all associated main contractors procedures are
completed and by ensuring safe access to work areas will be available through hoist lifts/access
ladders to carry out the work where ever main contractor site engineer’s & safety officers clearance
available.
4. LOGISTICS
MEP Subcontractor will deploy a dedicated team for the required logistics and material movement in –
out of the project.
5. HEALTH & SAFETY HAZARDS
Extreme Heat and Humidity
Mobile Equipment- Crane, forklift, etc. for material loading/offloading, transfer of materials to work
locations o Temporary electrical supply for lighting, use of power tools, etc.
Improper Stacking of materials DB, SMDB, Feeder pillars, etc.
Manual Handling / Offloading & Installation of DB, SMDB, Feeder pillars, etc.
Uninspected Power Tools
Unsafe working on Ladders
Poor Housekeeping& waste management
6. HEALTH, SAFETY AND ENVIRONMENT GUIDELINES
HSE Site Safety Inductions
Work supervisors shall ensure STARRT and RAMS are discussed with the workgroup prior to works
commencing
Safety toolbox talks
Environmental toolbox talks
Training courses (Internal and Third-party Training)
HSE Bulletin/HSE Site Notice Boards
Site Engineers, Site Supervisors, and Site Foreman
7. PERMITS AND CERTIFICATES
Hot work permit (Cutting/grinding)
Lifting Plan
Confined space
Working at heights/working on scaffolding – Supervisor to be trained by a third party.
Third-party certification for the operator and the equipment. Competence certification for workers.
8. DEFINITIONS
MS – Method Statement
QCP – Quality Control Procedures
ITP – Inspection and Test Plan
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ITA – Independent Testing Agency
DB -Distribution Board
SMDB – Sub Main Distribution Board
MEP – Mechanical Electrical & Plumbing
HSE – Health, Safety, and Environment
FP – Feeder Pillar
RAMS – Risk Assessment Method Statement
STARRT – Safety Task Analysis Risk Reduction Talk
9. RESPONSIBILITIES
9.1 PROJECT MANAGER
The project manager shall be responsible for overall project planning, procurement, technical
submissions, and drawing submissions.
The project manager shall coordinate activities within the site team and with the management for
the timely completion of activity in accordance with contract requirements.
9.2 CONSTRUCTION MANAGER
The construction manager is responsible for the work execution in compliance with the approved
method statement, HSE Risk Assessment, project specification, issued for construction drawings,
section, and details
9.3 SITE ENGINEER
The site engineer is responsible to carry out the work as per approved shop drawings and method
statements. He is also responsible to ensure adequate tool kits required for the works are in place
prior to the starting of work. The site engineer reports to the Construction Manager.
The site Engineer is responsible to ensure work has been done as per the specification and drawings;
inspections are carried out based on ITP and quality control procedure and coordinate with QA/QC
department for inspections.
The site engineer is responsible to ensure that all safety precautions are ensured in place and that all
personnel on-site are using the required personal protective equipment like helmets, gloves, shoes,
and reflective jackets. The site engineer in coordination with safety officers will ensure all relevant
permissions are taken prior to commencement of works.
The site engineers shall ensure that the works are supervised by a competent supervisor till the
completion of the task.
9.4 QA/QC DEPARTMENT
The QA /QC department will be responsible for overseeing the quality requirements and quality
control measures for the project in coordination with the project engineer and construction
manager.
Safety Engineer
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The SHE officer will be responsible for the safety, health, and environmental aspects on site as per
the project safety and environmental requirements/safety standards in coordination with the project
engineer and construction manager.
10. PROCEDURE / METHODS TO BE EMPLOYED:
10.1 SITE PLANNING & PREPARATION
Before installation takes place, the following pre-installation task is essential:
Identify and ensure that the pertinent document (e.g. approval for shop drawings, MEP coordination
drawings, wiring diagrams, (SMDB, DB & FP) load schedules, Schematic diagram & site development
overall plan power layout shall be available on the site) are approved.
Permits shall be applied prior to commencement of works.
Please ensure to obtain necessary PTW (Permit to Work), prior to allowing to work. Frequently
training should be conducted by the site supervisor/foreman. A daily safety briefing should be
conducted.
HIRA Compliance of control measures as stated on HIRA. Close monitoring of the activity to identify
any hidden hazards. The pre-task briefing shall be developed prior to commencing the activity.
Applicable permits shall be applied prior to the commencement of works.
The start of DB, SMDB, and Feeder Pillar installation shall be done in accordance with approved shop
drawings and properly coordinated with site engineers for the exact locations and levels. Marking on-
site to be carried out prior to commencement of installation works.
Conduct site safety briefing prior to commencement of work.
Identify and obtain appropriate installation tools and equipment.
Determine the staffing required and assign tasks to team members.
Perform lockout/tag-out procedures (where applicable) during installations.
10.2 HANDLING OF MATERIALS
Upon receiving the materials, all must be inspected and ensured that there are no manufacturing
defects and delivery damages.
Loading and unloading of the material shall be performed as per the manufacturer’s
recommendation. Use appropriate lifting equipment (e.g. crane, forklift, etc.) in unloading and
stacking/storing materials to and from the site stores/warehouse.
Ensure relevant Manufacturer’s Routine Test Certificates are available prior to/during delivery and
inspection.
Store DB, SMDB, Feeder Pillar, and MCC and its associated fittings/accessories in a clean and dry area
to prevent condensation. Do not allow the materials to contact with corrosive fumes, liquids, salts, or
concrete. It must be stored off the ground and securely covered to provide protection from dirt and
moisture. DB, SMDB, and Feeder Pillar location, as possible, keep the packaging/pallet intact and lift
using proper lifting equipment or manually with an adequate number of people. Handle with care to
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avoid damage to internal components and the enclosures. (Follow handling guidelines recommended
by the manufacturer).
DB, SMDB, Feeder Pillar, and accessories shall be properly supported and stacked on a flat surface
(follow manufacturer manner of stacking), should not be laid directly to soil/ floor.
Store the materials in the manufacturer’s original packaging in the manner that labels are so
arranged for easy identification, to avoid mismatches of loose components.
Only required materials to be shifted to site and store temporarily ensure extra materials are not
dumped to site and congest the working area.
Once work is completed extra materials and tools are to be returned back to stores, work is to be
kept clean.
10.3 PRE-INSTALLATION WORK
All workers to attend safety induction training on the safe installation methods by the safety
department.
Ensure that Distribution Boards, Feeder Pillar & Main Distribution Board is as per approved material
schedule.
Ensure all Distribution Board, Feeder Pillar & Sub Main Distribution Board received are inspected
from Consultant and found acceptable as per approved materials submittal
Ensure all drawings are the latest revision, approved for construction issue, and are fully co-
coordinated with all other services and installations
Confirm that the type, schedule, and rating of distribution boards are correct and as per project
specification and approved material submittal before commencing the installation works.
Make arrangements to provide manufacturer’s installation manuals prior to starting the installation
work.
Prior to commencing any works, a risk assessment must be conducted, taking into account all
possible risks and the appropriate precautions put in place, i.e. fire extinguishers, fire blankets, safety
harnesses, etc. Refer to the risk assessment/risk management section of this method statement.
Ensure DB, Feeder Pillar & SMDB installation shall be done exactly as per the approved construction
drawings
Coordinate with the civil scope contractor due to the requirement of the wall and surface finishing.
All works shall be undertaken in a neat and workmanlike manner to ensure a quality installation.
Immediately before being installed, Distribution Boards will be checked for damages.
Permit to work system to be followed if required Proper PPE to be worn by all operatives always on
site.
10.4 INSTALLATION OF SMDB, FEEDER PILLAR, AND DB
Ensure the installation of the Distribution Board, Feeder Pillar, and Sub Main Distribution Board are
as per approved shop drawings and coordinated with other services.
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Ensure prior to installation all DB/SMDB/Feeder Pillar is approved from the consultant and is free of
damages.
The location should be marked for the installation of the DB/SMDB/Feeder pillar as per approved
shop drawings.
Ensure that the area is clear and barricaded off from other construction activities and that are
overhead installations are completed.
Verify the DB/SMDB/Feeder pillar are tagged correctly before they are prepared for site installation
as per project specification.
Mount DB at a height not less than 1200mm from finished floor level to bottom of the DB and the
maximum height of this DB shall be 2200mm from finished floor level to top of DB unless shown
otherwise on approved drawings/schedules.
Other Panelboards, Feeder pillar / SMDB elevation should be conforming to the approved
detail/drawings.
Drill holes on the wall and install the bolts. The size of bolts should depend upon the size of the
distribution boards and should be as approved detail drawing.
Proper DB dressing shall be made so that there are no free cables hanging inside the DB.
10.5 INSTALLATION OF SURFACE MOUNTED DB, SMDB
Drill holes on the gypsum wall/masonry wall (as per site requirement) and install the channels place
DB and SMDB to be fixed against the wall with bolts /nuts/washer and tight properly. The size of
support should depend upon the size of the distribution board and SMDB.
Fix mounting bolts through the DB/SMDB and secure them in place (ensure mounting height meet
the approved/specified).
Adjust for proper level and alignment. A distance of not less than 750 mm shall be provided and
maintained in front of every switchboard (SMDB) for the purpose of safely and effectively operating
and adjusting all equipment mounted thereon.
Trunking/cable tray may be fixed between the DB/SMDB and ceiling or floor level to dressed and
accommodate the entry of wire/cables to the panel (refer to the approved detail drawings) ensuring
the adequate earth continuity shall be made between the trunking/tray and the DB/SMDB enclosure.
Carefully pull wires and cables within the panel board.
Install DB/SMDB internal components, making sure that wires/cables are not to be damaged and vice
versa.
Ensure wires/cables are to be dressed and should conform to the approved DB/SMDB schedule.
Ensure MCB/MCCB are correctly labeled as per corresponding approved schedules.
Install panelboard front cover trim. Adjust trim for proper alignment with building lines.
Identification labels should be applied correspondingly to all DB/SMDB as per approved shop
drawings.
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Appropriate touch-up paints (approved/manufacturer supplied) should be applied for any surfaces
damaged during the installation process to restore the integrity of the panel’s surfaces in a neat and
acceptable process.
10.6 FLUSH (RECESSED) INSTALLATION
Drill holes on the Gypsum wall and install the channels to be fixed against the wall with bolts
/nuts/washer and tight properly support the DB and SMDB. The size of support should depend upon
the size of the distribution board and SMDB.
Flushing preparatory works should be stringently done in order to avoid rework or unnecessary
concrete cutting (or chipping) that may affect the integrity of the wall structure. Hence it is advisable
to provide only block-outs (thru styrofoam) with acceptable allowance (ensure very minimal gap
should be provided) to accommodate the flush type DB/SMDB enclosure within this designated final
location.
Remove the temporary block-out, and clean the surfaces not to damage the concrete and expose the
wall reinforcement bar.
In order to protect internal components, it is advisable to remove them properly and layout the
enclosure to the flush/block out. Carefully protect the dismantled internal components and store
them in secure storage away from water contamination and properly label it for easy reference.
Install appropriate bracketing (strut channel, stud, threaded rod, etc. recommended by the
manufacturer), ensure approval and civil discipline (as applicable). Check leveling and orientation as
per approved shop drawing and project specification.
Appropriate plastic coverings should be provided to ensure the DB enclosure will not be damaged,
contaminated by concrete, and/or deformation. Final adjustment is to be done as per approved
elevation, provide as possible support holding the DB enclosure during mortar fill application.
Dressed properly the containment entry to the panel, provide appropriate sleeves between DB and
home runs.
10.7 FEEDER PILLAR
Installation area shall be isolated and only authorized persons to be allowed, barricades and warning
signs shall be provided for the same.
Loading/unloading of the panels shall be as per manufacturer recommendations. Use appropriate
lifting equipment in bringing the materials from the storage to the permanent base/location.
Plywood (or appropriate floor protection) shall be placed on the floor in order to protect the floor
from possible damage while moving.
Installation works shall be carried out only with respect to the approved shop drawing of the latest
revision. It shall be supervised by a competent Engineer/specialist and/or manufacturer’s
representative.
All components of Feeder Pillar such relays, fuses, CT’s meter, etc. shall be verified against the
approved material submittal and relevant shop drawing.
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Ensure the floor surface is ready with base frames/accessories properly coordinated with the panel
base dedicated fixation point.
Mark support fixation as per approved method and shop drawing.
For external feeder pillar-based panel boards, coordinate sizes and locations of concrete bases with
actual equipment provided. Cast anchor-bolt inserts into bases. Concrete, reinforcement, and
formwork requirements are specified with concrete as per the approved drawing.
Install the panel, lift it and place it on its dedicated base using appropriate equipment, following
manufacturer recommendation.
Ensure minimal/specified surrounding clearances shall be maintained specifically at the access side of
the panel for easy accessibility for termination of cables and other maintenance works can be carried
out.
Check cabinet interconnections, Busbar connections, control connections between cubicles after
proper alignment of the sections as per manufacturer’s drawing and approved shop drawing.
All knockouts made on the panel covers shall be cleaned from burs/sharp edges and appropriate
touches up are applied. Fix firmly the corresponding cable with suitable approved glands and ensure
earthing connectivity.
Ensure allowable bending radius for all cables being gland are followed as per cables’ manufacturer
recommendation (normally 8 times the cable diameter) and cables are rigidly fixed with proper
support to avoid unwanted exertion of force and deform the Panelboard coverings
Cable pulling, termination, and crimping should be done as per the cables/wires method statement.
All feeder pillars shall be provided with proper earthing connections as per approved shop drawings.
The manufacturer’s representative to verify the site installation and provide acceptance of the same
prior to final Testing and Commissioning/Energization.
Necessary covering/warning signs and tapes should be provided once the installation is completed to
protect the panels from dust, water contamination, concrete, etc. that may cause early deterioration
or damage on it.
10.8 ISOLATORS
Mark the location of isolator or disconnect switch on wall or ceiling. The location shall be as per the
approved drawings and has been coordinated with other services.
Fix the channel support on the wall then fix the isolator or disconnected switch as per approved
standards and coordinate with other services.
Ensure that the isolator switch is aligned and fixed properly. Terminate the incoming and outgoing
cables using approved accessories.
Terminate the earthing of isolator brackets and other metallic parts and ensure that earthing has
continuity up to the final sub-circuit.
A continuity test shall be conducted to ensure the proper working operation of the isolator. Isolator
shall be chosen depending on the installation is (outdoor or indoor). Ensure that the isolator
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intended for outdoor shall minimum of an IP65 rating and shall comply with the requirements as per
project specifications.
Cover or protect all installed isolators to prevent the accumulation of dust and debris during
construction.
Ensure that workmanship is neat and clean and complying with good construction practices.
Where enclosure is installed in direct sunlight sunshades of an approved design shall be provided.
Raise inspection request when work is completed (per sections/areas) for installation of wiring
accessories.
10.9 IDENTIFICATION AND TERMINATION
Identify field-installed wiring, and components; provide warning signs as specified as per relevant
sections.
Sub Main Distribution Board (SMDB) Nameplates: Label each Sub Main Distribution Board
compartment with engraved metal or laminated-plastic nameplate mounted with corrosion-resistant
screws.
Install cable entries of DB, feeder pillar & SMDB panel shall be either bottom or top or both as per
the requirement and site condition.
Brass compression type cable glands shall be used for glanding cables.
Internal & external compression cable glands shall be provided with PVC shrouds.
The number of strands of the cable core shall not be reduced at the termination point.
Compression-type cable lugs shall be used for termination.
Lugs shall be insulated with an approved type of insulation tape or heat shrinkable sleeve after
crimping the lugs before termination.
The insulation tape or heat shrinkable tube shall have equal or better electrical and mechanical
properties than those of the original insulation removed.
Sufficient spare cable shall be allowed to remake the termination.
SMDB, DB, & FP Nameplates should comply with requirements for identification specified in project
specifications, approved material, and shop drawing.
Cable terminations are accessible and cable identification tags shall be provided at both ends of the
cable.
Cables shall be tested for continuity and insulation resistance test before and after termination.
10.10 CONNECTIONS
Install equipment-earthing connections for Distribution Board, Feeder Pillar & Sub Main Distribution
Boards with earth continuity to main electrical earth bus.
Tighten electrical connectors and terminals, including screws and bolts, according to manufacturer-
recommended torque-tightening values. If the manufacturer’s torque values are not indicated, use
those specified in applicable standards.
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The cable gland, termination lug, heat shrinkable, etc. all the cable/wire termination and labeling
material shall be as per approved materials and project specification.
On completion of installation, inspect interior and exterior of panels and all system components.
Remove paint splatters and other spots. Vacuum dirt and debris; do not use compressed air to assist
in cleaning.
Repair exposed surfaces to match the original finish. Clean components internally using methods and
materials recommended by the manufacturer.
11. TRAINING
All required training for stipulated installation activities are provided to all technical staff for ensuring a
quality workmanship
12. WORKING HOURS
Site operational time shall be followed as per project progress requirements, all relevant local
authority schedules of holidays are to be observed. Comply with regulations regarding summer
working hours (Working in direct sunlight during hot weather conditions).
13. HOUSEKEEPING
Working areas will be kept clean by disposing of the waste materials at the designated areas. At the
end of the days’ work, the installation supervisor will ensure that the debris is disposed of during the
course of the activity on regular basis.
Dust created by work e.g. drilling, of the slab, grinding, and polishing. The area must be isolated
/protected by a green net and required additional PPE for the operatives.
Any materials stacked in the site shall neither obstruct the emergency evacuation route.
14. MANPOWER
Subject to main contractors’ programmer and scope/area available for MEP activities, but not limited
to below:
Electrical QA/QC Engineer
Safety Engineer/Officer
Riggers
Equipment Operators
Painter
Foreman
Charge hands
Electricians
Scaffold erectors
Welder
Helpers
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15. MATERIAL REQUIREMENTS
Distribution boards, Panelboards, Switchboards, Feeder pillar, ACB, MCCB, MCB, Relay, Pilot lamps,
Volt Meter, Ammeter, etc.
Control cables/wires and accessories
Cables wires and accessories
Bolt, nuts, and washers
Plugs and screws
Anchor bolts/hammer set anchor
Strut channels
Threaded rods
Touch-up paint
16. PERSONAL PROTECTIVE EQUIPMENT REQUIREMENTS
Safety helmet
Safety goggles
Safety boots
High visibility
Vest
Hand gloves
Earplugs
Respiratory protection
Full body harness
17. PLANT & EQUIPMENT REQUIREMENT
The following equipment’s and materials shall be used for the works:
Standard Electrician Tools
Electric Drill and set of bits
Cutting Tools
Set of wrenches
Set of files
Hammer
Plumb bob/Spirit level
Air Blower/Vacuum Cleaner
Measuring tape
Hand gloves
Lifting Equipment (e.g. mobile crane, forklift for loading and unloading during delivery/shifting)
Cable termination kit
Torque wrench
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Ladders
Scaffolding
Welding Machine
Notes:
Third-party certification(competence certificates) for workers, operators, Equipment valid registration,
insurance, and fitness certificates, operator daily inspection checklist should be available for Safety
officer validation before commencing the works.
18. QA/QC APPROVAL
Follow approved Method Statement, ITP, QCP, HSE Plan, and Material Approval & Checklist.
19. SUPPORTING DOCUMENTS
This method statement is to be read in conjunction with the below-referenced documents
Project specification & approved drawings.
Project Quality Plan
Project HSE Plan
20. ATTACHMENTS
Risk Assessment
Inspection & Test Plan
Quality Control Checklist
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METHOD STATEMENT FOR
BUILDING MANAGEMENT SYSTEM
SR. EFFECTIVE REV. MSS MANAGER MSS PROJECT CLIENT
CLIENT QA/QC
NO. DATE NO. QA/QC MANAGER SUPERVISOR
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BUILDING MANAGEMENT SYSTEM
1. PURPOSE
The method statement for BMS – Building Management System identifies the materials, procedures,
and requirements for installation, storage, handling, and cable testing system.
This method statement ensures that quality control objectives are maintained, and accurate records
are established for all related activities.
2. SCOPE
A building management system (BMS) is a computer-based system that manages and monitors
equipment such as air conditioning, ventilation, heating, lighting, security devices, power systems,
Internet of Things (IoT) sensors, energy, and gas meters.
Servers, supervisory devices, field buses, controllers, inputs, and outputs are all part of a traditional
BMS. Building Automation Systems (BAS) is another name for them. A building management system
(BMS) integrates the HVAC and other building systems to work as a single unit. They should, ideally,
consolidate activities and make data visualization easy via a user interface or console.
3. REFERENCES
This method statement is subject to the requirements as stated in the following regulatory & statutory
documents, applicable standards, specifications, and building codes:
Project Specification
Project approved materials/shop drawings/IFC drawings
Approved Emergency Response Plan, Waste Management Plan, HSE Plan
4. ACESS/EGRESS
Works will be started or carried out only when all associated main contractors’ procedures are
completed and by ensuring safe access to work areas will be available through hoist lifts/access
ladders to carry out the work wherever main contractor site engineer’s & safety officers’ clearance
available.
5. LOGISTICS
MEP Subcontractor will deploy a dedicated team for the required logistics and material movement in–
out of the project.
6. HEALTH, SAFETY & ENVIRONMENT
Extreme Heat and Humidity
Extreme cold, high winds, and dusty condition
Mobile Equipment- crane, forklift, etc. for material loading/offloading, transfer of materials to work
locations.
Temporary electrical supply for lighting, use of power tools, etc.
Improper stacking of materials cable trucking, trays, fittings, etc.
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Uninspected Power Tools –drilling of holes for anchors, installation of hangers, cutting of cable
trunking, cable trays, etc. as per approved drawings
Unsafe working on ladders
Unsafe storage/handling/application of chemicals – Zinc Coating
Poor housekeeping& waste management
7. PERMITS AND CERTIFICATES
All required statutory permits like safe work permits, power tool work permits, height work permits
building permits, environmental permits, and water tapping will be obtained for the project.
All internal permits for shutdowns and other related activities will be obtained through coordination
with all concerned parties.
The work will commence upon approval of this Method Statement for BMS – Building Management
System; hence, no special permits or licenses are required.
However, the Project Manager and site team will ensure compliance with the client’s HSE
requirements.
Barricades/ will be provided sufficiently and maintained, as precautionary measures during the entire
stage of work.
A barricade will be made to indicate the construction boundary.
Toolbox meetings shall be organized and documented prior to mobilization of the workforce.
Prior to using any machines/equipment at the site, ensure that they will be inspected and certified by a
third party as per the client’s requirements.
Ensure periodic preventive maintenance will be made on all equipment and machines.
Hot Work Permit system will be strictly implemented and without which work cannot proceed.
Regularly check that safe working condition is obtained prior to working.
8. DEFINITIONS
SCS-Smart Communication Systems
MS – Method Statement
QCP – Quality Control Procedures
ITP – Inspection and Test Plan
ITA – Independent Testing Agency
BMS – Building Management System
HSE – Health, Safety & Environment
QA/QC – Quality Assurance/Quality Control
PPE – Personal Protective Protection
MEP – Mechanical, Electrical & Plumbing
DDC – Direct Digital Controller
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9. RESPONSIBILITIES
8.1 PROJECT MANAGER
The project manager shall be responsible for overall project planning, procurement, technical
submissions, and drawing submissions,
The project manager shall coordinate activities within the site team and with the management for
the timely completion of activity in accordance with contract requirements.
8.2 CONSTRUCTION MANAGER
The construction manager is responsible for the work execution in compliance with the approved
method statement, HSE Risk Assessment, project specification, issued for construction drawings,
sections, and details.
8.3 SITE ENGINEER
The site engineer is responsible to carry out the work as per approved shop drawings and method
statements. He is also responsible to ensure adequate tool kits required for the works are in place
prior to the starting of work. The site engineer reports to the Construction Manager.
The Site Engineer is responsible to ensure work has been done as per the specification and drawings;
inspections are carried out based on ITP and quality control procedure and coordinate with QA/QC
department for inspections.
The site engineer is responsible to ensure that all safety precautions are ensured in place and that all
personnel on-site are using the required personal protective equipment like helmets, gloves, shoes,
and reflective jackets. The site engineer in coordination with safety officers will ensure all relevant
permissions are taken prior to commencement of works.
The site engineers shall ensure that the works are supervised by a competent supervisor till the
completion of the task.
8.4 QA/QC DEPARTMENT
The QA/QC department will be responsible for overseeing the quality requirements and quality
control measures for the project in coordination with the project engineer and construction
manager.
8.5 SAFETY ENGINEER
The HSE Officer will be responsible for the safety, health, and environmental aspects on site as per
the project safety and environmental requirements/safety standards in coordination with the project
engineer and construction manager.
10.METHODOLOGY
9.1 SITE PLANNING & PREPARATION
Before installation takes place, the following pre-installation task is essential:
All clearances must be obtained and approved from all trades (i.e. Safety, Civil, Architectural,
Mechanical, and Electrical) prior to commencing of works. Once the necessary clearances were
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obtained, work at the site will start with reference and compliance to the approved shop drawings
and materials approval.
All equipment required is available and shall be unloaded and positioned in the location where the
works are taken place and as specified in the drawings and site requirements. All materials are
available and shall be unloaded, laid, and positioned in the area/location specified in the drawings
and installed as per work methodology.
MEP coordination drawings are available to be followed for proper coordination between services.
Concern Personnel/Engineer to coordinate and communicate between each other for proper work
execution and smooth operation at the site. This is to avoid any unforeseen issues and/or problems
that might affect the work quality and progress.
9.2 HANDLING OF MATERIALS
Store all wires and cables indoors in a clean, dry location, if possible, and protect from moisture,
construction equipment, falling objects, chemical spills, moving vehicles, and other hazards.
Do not store coils or reels flat. Store coils upright and reels upright on their flanges.
Physically check that the material and the quantities received to comply with the technical
requirements of the purchase order.
Mark or label damaged or incorrect materials should only be replaced and segregated by placing
them in a designated quarantine area pending resolution for replacement from the manufacturer.
Check to lay down area is clean and secured for any possible damage to the material and the storage
area is protected from moisture and dirt.
Inspection of material delivery will be conducted, and Material Receiving Report will be prepared.
The material storage at the site shall strictly follow the guidelines issued by the manufacturer. The
environmental conditions and documentation shall be as per the methods described in the relevant
documents. It is important that in the case of electronic boards, proper handling care will be taken.
All such components are shipped with static protection covering, which should not be removed until
the device is ready for installation. If this cover is removed for inspection, no parts in the circuitry
should be touched and the cover should be replaced after inspection.
10. BMS INSTALLATION
10.1 INSTALLATION PROCEDURE:
Ensure installers are to wear the required protective shield, PPE (hand gloves, safety goggles, dust
mask, hard hats, safety shoes, coverall full-body harness, etc.)
All the responsible persons with the architect and electrical engineer should be present at the time of
installation with the approved method statement to ensure the proper installation.
Before commencing the work, make the final marking with proper dimension and get approval on
the final marking.
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Cabling to be made using the selected routing and correct type of cable as per the approved drawing
and material submittal.
Install the following components as instructed in the given manufacturer’s manual.
Installation shall be carried out by supplier competent personnel in accordance with good industry
practice, and project specification.
10.2 CABLE INSTALLATION
Cable installation shall be based on approved shop drawings, IO point schedule & System
Architecture. The Site Supervisor will instruct the installation/ erection team supervisor regarding the
cable laying procedure & will distribute the drawings/ layouts for the work.
METHOD OF CABLE LAYING
Drop vertical cables down rather than pulling them up whenever possible. Support cables at frequent
intervals to prevent excess stress on the jacket. Support can be provided by cable ties (tightened
snugly, not tightly enough to deform the cable jacket). Use service loops can assist in gripping the
cable for support and provide cable for future repairs or rerouting.
COMMUNICATION CABLE – This cable will be used as a communication cable between DDC Panel to
equipment which is integrated using software provisions like Modbus RS 485, BACnet MSTP, etc. This
cable will be laid in the surface-mounted GI conduits / concealed PVC Conduit or cable trunking
Containment.
SIGNAL CABLE – (for Analog Input/ Output/Digital Input)-This cable will be used as signal cables
between the DDC panel and field devices/ sensors. All the sensors like Temperature sensor, VFD
speed control, DP switch across the filter, DP switch, etc. shall be originated from the DDC controller
panel & will be laid in the cables trays/ surface mounted GI conduits / concealed PVC Conduit at the
panel end. At the sensor end, these cables will be taken out from the cable trunking/ surface
mounted GI conduits / concealed PVC Conduit and laid in the flexible GI conduits till the sensor and
later will be terminated.
Signal cable – (for Digital Output/ 24v Power) -This cable will be used as a signal cable between the
DDC panel and field devices. All the devices like the on/off command etc. shall be originated from the
DDC controller panel & will be laid in the cables trunking/surface mounted GI/PVC conduits at the
panel end. At the device end, these cables will be taken out from the cable trunking/surface
mounted GI conduits and laid in the flexible GI conduits till the sensor and later will be terminated.
11. CABLE CONTINUITY TESTING
Once the cable pulling is done between DDC Panel to any Field Sensor, the cable will be tested for
continuity.
II. DDC PANEL WITH CONTROLLER INSTALLATION
The Site Supervisor will instruct the installation/erection team supervisor regarding the installation
procedure & will distribute the approved drawing/product catalog/manufacturer recommendation.
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The installation team will install the DDC panel according to the approved construction drawing or
product catalog.
All the cable terminations in the controller will be with proper size lugs & proper ferrules.
Electrical earthing will be ensured for the DDC panel.
RJ45 port will be ensured for the DDC panel.
The site supervisor will check the work.
Any deviation from the Approved Construction drawings due to site conditions will be noted down and
will be incorporated in the as-built drawing.
III. BMS FIELD DEVICES INSTALLATION
Installation Of Protection Pocket with Immersion Temperature Sensor (QAE2112.010+ ALT-SS100)
12. MOUNTING INSTRUCTIONS:
The sensor should be installed in an elbow such that the immersion rod or the protection pocket faces
the direction of flow. The water must be well mixed where the temperature is acquired. This is
downstream from the pump or, if the pump is mounted in the return, at least 1.5 m after the mixing
point.
Marking will be done on the chilled water pipes.
The hole is drilled into the pipe where the thermowell is needed.
To fit the sensor, a threaded fitting or T-piece G ½ must be welded into the pipe.
A thread sealant such as Teflon tape or pipe dope is applied to the outside threads of the thermowell
The thermowell is inserted into the threadolet and tightened.
The protection pockets may not be filled with oil. Use of thermally conductive paste or similar inside
the pockets is not permitted
An immersion temperature sensor will be supplied and installed into the thermowell socket.
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Cables will be pulled/ laid up to the immersion-type temperature sensor from the DDC controller
through surface GI Conduits or cable trunking as required.
INSTALLATION OF DUCT SENSOR FOR HUMIDITY & TEMPERATURE (QFM2160)
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13. MOUNTING INSTRUCTIONS:
Marking will be done on the air duct with the necessary holes for installation.
Ensure that the sensor is installed in locations as per BMS Design
Mount the sensor in the center of the duct wall.
It shall be ensured that the sensor is mounted on the middle of the duct wall or in locations where the
airflow is stable or smooth.
A hole shall be made and the mounting flange shall be fitted.
The duct sensor consists of a housing, a printed circuit board, connection terminals, a mounting flange,
and an immersion rod having a measuring tip.
The measuring circuit and the setting element are accommodated on the printed circuit board inside
the cover, the connection terminals on the base.
The immersion rod and housing are made of plastic and rigidly connected.
Cable entry is made via the cable entry gland M16 supplied with the sensor, which can be screwed into
the housing.
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INSTALLATION OF ROOM SENSOR FOR HUMIDITY & TEMPERATURE (QFA3160 + AQF3100)
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14. MOUNTING INSTRUCTIONS:
The room sensors have been designed for wall mounting.
Mount the sensor on the exterior wall; if possible in the middle of the wall, at least 1.5m above the
floor and at least 50 cm from the next wall. Not above or below windows, above doors and ventilation
shafts, below balconies or eaves.
INSTALLATION OF DIFFERENTIAL PRESSURE SWITCH (QBM81-XX)
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15. MOUNTING INSTRUCTIONS:
For installation of the Differential Pressure Switch, necessary markings for the holes will be done on
the AHU body for making holes to fix the differential pressure switch.
DP Switch will be supplied and will be fixed on the holes drilled on the AHU / Ducts.
Sampling tube & joining pipes will be supplied along with DP switch and fixed at correct locations for
proper sampling.
Cables will be pulled up to the DP switch from the DDC controller through Conduits or cable trunking
as per shop drawing.
A cable connection will be done as per the DP switch manufacturer’s catalog/ datasheet provided with
the DP switch.
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INSTALLATION OF LIQUID PRESSURE SENSOR (QBE2003-P4)
16. MOUNTING INSTRUCTIONS:
The pressure sensor consists of a pressure connection external thread G ½” and inside thread M5.
The electrical connection shall be made through the sensor hood with DIN EN 175301-803-A plug-in
connection.
Appropriate measures must be taken to ensure a leak-proof fitting. To provide for test measurements
without leakage of the medium, it is strongly recommended that an appropriate test adapter and
shutoff device be fitted. The tapping point should be at the side, near the bottom of the pipe. Do not
measure the pressure from the top of the pipe (where it may be affected by airlocks) or the bottom
(where it may be affected by dirt).
The tapping point should be at the top so that no condensate reaches the sensor.
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INSTALLATION OF WATER DP SWITCH (PL-FD113)
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17. MOUNTING INSTRUCTIONS:
The PL-FD113 should only be connected by a competent, suitably trained technician, experienced in
installation with hazardous voltages. (>50Vac & <1000Vac or >75Vdc & 1500Vdc). Pressure
connections should be carried out by a technician qualified to work with the media being monitored.
Ensure that all power is disconnected before carrying out any work on the PL-FD113.
Ensure that the unit is not subjected to ingress by water.
Mount the PL-FD113 using the screws supplied. If the supplied screws are lost, an M4 x 6 screw can be
used. This must have a depth of 5mm (0.2”) or less.
Connect pipework using ¼” BSP male adapters into the ¼” BSP female fittings on the switch. Low-
pressure connection is at the top of the switch and the high-pressure connection at the bottom as per
the diagram below
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Set the switching point by inserting a screwdriver into the slots wheel above the scale
INSTALLATION OF WATER FLOAT SWITCH (CFS2-ONBPN-20 + A-45)
7)
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INSTALLATION FOR ROTARY AIR DAMPER ACTUATOR (GLB146.1E)
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18. MOUNTING INSTRUCTIONS:
Ensure that the diameter of the damper shaft is within the allowed limits.
Determine the direction (CW or CCW) in which the damper shaft rotates to open the damper. The
installation procedure varies depending on the damper direction.
Determine the angle of the damper opening.
Set the mechanical end limits.
Mount the controller on the damper shaft and lock by tightening the screw.
iv. Installation of Operator Workstation and Printer
Operator workstations will be installed as per System Architecture Rooms on the desk (provided by
others).
The operator workstation shall be connected to the existing power sockets provided.
Design CC graphics software will be loaded on the operator workstations.
Required TCP/IP LAN points for communication will be provided through the network.
Printers will be installed as per System Architecture Rooms on the desk (provided by others).
19. INSPECTION
A request for inspection shall be raised upon completion of a system or apart.
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20. TRAINING
All required training for stipulated installation activities are provided to all technical staff for ensuring a
quality workmanship
21. WORKING HOURS
Site operational time shall be followed as per project progress requirements, all relevant local
authority schedule of holidays is to be observed. Comply with government regulations regarding
summer working Hours (Working in direct sunlight during hot weather conditions).
22. HOUSEKEEPING
Working areas will be kept clean by disposing of the waste materials at the designated areas. At the
end of the days’ work, the installation supervisor will ensure that the debris is disposed of during the
activity on regular basis. Dust created by work e.g., drilling, of the slab, grinding, and polishing.) The
area must be isolated/protected by a green net and required additional PPE for the operatives. Any
materials stacked in the site shall neither obstruct the emergency evacuation route.
23. MANPOWER REQUIREMENT
Subject to main contractors’ programmer and scope/area available for MEP activities, but not limited
to below:
Site Engineer
Supervisor/Foreman
Technicians
Helpers
24. MATERIAL REQUIREMENT
Ensure material being used is of the approved manufacturer from the project vendor list and of quality
as specified All the material to be used as per the approved materials submittal, shop drawings, and
specification requirements.
All approved equipment as per design drawing & material submittal.
Personal Protective Equipment Requirement
Safety Helmet
Safety Goggles
Safety Boots
High Visibility Vest
Hand Gloves
Ear Plugs
Respiratory Protection
Full body harness
Plant & Equipment Requirement
The following equipment and materials shall be used for the works:
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Ladders
Scaffolding
Screwdrivers – Flat, Positive, (Various Sizes)
Stanley Knife + Blades (Retractable)
Pliers
Side Cutter Pliers
Mastic Gun for Silicone Sealant
Tape Measure 5m
Tool Belt
Marker Pen Pencil
Dustpan and Brush
Multimeters
Notes:
1. Third-party certification (competence certificates) for workers, operators, equipment valid
registration, insurance, and fitness certificates, operator daily inspection checklist should be available
for safety officer validation before commencing the works.
25. QC APPROVAL AND OTHER DOCUMENTARY REQUIREMENTS
Follow approved Method Statement for Building Management System, ITP, QCP, HSE Plan, and
Material Approval & Checklist.
Supporting Documents
This Method statement for BMS – Building Management System to be read in conjunction with the
below-referenced documents, contract specification & approved drawings.
Project Quality Plan
Project HSE Plan
26. ATTACHMENTS
Risk Assessment
Inspection & Test Plan
Quality Control Check Lists
Project Organization
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METHOD STATEMENT FOR
FUEL TANK INSTALLATION
SR. EFFECTIVE REV. MSS MANAGER MSS PROJECT CLIENT
CLIENT QA/QC
NO. DATE NO. QA/QC MANAGER SUPERVISOR
FUEL TANK INSTALLATION
PURPOSE
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The method statement for fuel tank installation defines the sequence and describes the health, safety,
environmental, and control procedures to be followed.
1. DEFINITIONS
CM Construction Manager
QC Quality Control
HSE Health, Safety & Environment
PPE Personal Protective Equipment
PMV Plants, Machinery & Vehicles
LPS Loss Prevention System
2. REFERENCE
Information sources may include, but not be limited to, verbal or written and graphical instructions,
signage, work schedules/drawings/specifications, work bulletins, charts and hand sketches, and
Material Safety Data Sheets (MSDS).
HSE Plan
CEMP
General Lifting Plan
HSE General Requirements
Traffic Manual
Manual of Uniform Traffic Control Devices
3. RESPONSIBILITIES
3.1. PROJECT MANAGER
Responsible for accomplishing the stated project objectives which include creating clear and
attainable project objectives, building the project requirements, and managing the constraints of the
project management triangle, which are cost, time, scope, and quality.
The Project Manager shall be responsible for ensuring that the Project Quality Plan and the
Inspection and Testing procedures, method statement, HSE safety, and all contractual
documentation are maintained up to date and accessible to all parties.
3.2. CONSTRUCTION MANAGER
Responsible for overall construction activities ensuring that all quality and safety procedures are
implemented and required approved permits are obtained.
3.3. SITE ENGINEER
Supervise operations in accordance with the approved method statement, shop drawings,
specifications, material submittals, and schedules to achieve the acceptance of the project
deliverables.
3.4. SITE SUPERVISOR
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Supervise closely, the activities designated to them and ensure that all instructions and safety
procedures are followed and strictly adhered to.
3.5. SITE FOREMAN
To liaise with the Site Engineer and Supervisor for the work execution.
3.6. QA/QC ENGINEER
Ensure the proper implementation of the Quality system and monitor the overall quality of the work
is maintained. Conduct inspection and monitor tests. Determine and report any non-conformance
and recommended corrective actions. Ensure that all personnel is aware of the quality requirement.
Training of relevant personnel.
Conduct surveillance and inspection duties at various stages to ensure compliance to QA/QC Plan.
3.7. HSE MANAGER
Health, safety, and environmental (HSE) manager generally plan, coordinate and implement issues
and directives within the organization. He ensures safe environmental working conditions for all
employees.
3.8. HSE ENGINEER
Ensure enforcement of safety procedures in accordance with the approved HSE Plan. He will be
closely monitoring the site engineer’s strict implementation of the method statement and risk
assessment, the use of proper tools and equipment
Maintain safety, certifications of equipment and their adherence to safety regulations, reporting of
any unsafe work or stopping work that does not comply with ES&H procedures.
Advice for health & safety requirements and monitor the hazard controls implemented on-site as per
the method statement for fuel tank installation and risk assessment.
4 .RESOURCES
Plant and Equipment
Crane
Flatbed Truck
Water Truck
Compactor
Concrete Pump
Concrete Transit Mixer
Concrete Vibrator
Note: All 3rd Party Certificates shall be inspected prior to commencing lifting operation.
Work Force
Site Engineer
Foreman
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Equipment Operator
Rigger
Banksman
Security Guards
Helpers/Laborers
Safety Engineer
First Aider
Light Tools
Power Tools (Various)
Hand Tools (Various)
Materials
Warning Signs
Warning Tapes
Emergency Kits
5 Sets Fuel Tank (50,000 liters each capacity, approximately 5 tons each when empty) including steel I-
Beam upstand
C40 Concrete
Hessian Cloth
200mm x 400mm x 200mm Concrete Blocks
Steel Mesh 10mm ø
Bolts and Nuts
(Test Certificates for the above materials are not applicable since these are only for temporary works
and do not require full control of QA/QC.)
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5. METHODOLOGY-METHOD STATEMENT FOR FUEL TANK INSTALLATION
1. FUEL TANK SPECIFICATIONS
STATIONARY DIESEL FUEL TANKS
Diesel storage tank requirements for the project: Bund Wall Dimensions
Diesel Tank Capacity Length mm Width mm Height mm
2,500 L 4,000 3,000 400
5,000 L 5,300 3,500 400
10,000 L 5,000 5,000 600
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15,000 L 7,000 5,000 600
20,000 L 9,000 5,000 600
50,000 L 14,500 7,000 600
Prior to commencing installation of the fuel tanks, full coordination with the concerned government
agency is required. Ensure that all requirements have been complied with and fully coordinated during
the course of the tank installation.
The area where the fuel tank will be placed shall be in accordance with the inspection requirements as
follows:
Storage tank bund wall should be constructed using concrete material and should be plastered inside
& outside and the concrete base should be 10-centimeter thickness. A fabricated steel plate bund wall
is also allowed.
Bund wall drain pipe should have a valve with a pipe blind cap installed at all times.
Bund wall should be painted with standard caution stripes.
A 3-meters free open space should be maintained around the bund wall.
Dry chemical powder and foam fire extinguishers are to be placed 5 meters away from the storage
tank and to be installed inside industrial-type boxes.
The required quantity of fire extinguishers for each tank capacity is as per below:
2,500/5,000 liters capacity storage tank = 2 x 6 kg Chemical Powder
15,000/10,000/20,000 liters capacity storage tank = 2 x 12 kg Chemical Powder
50,000 liters capacity storage tank = 1 trolley 20 gals Foam Chemical & 2 x 12 kg Chemical Powder
No electrical connections inside the bund wall area are allowed. All pumps & meters should be
installed outside the bund wall area.
There should be designated legal parking for fuel road tankers and easy access in/out from the site.
The contractor is fully responsible for all the mandatory safety and environmental measures related to
on-site diesel product handling.
6. SITE PREPARATION
1. The 5 sets of fuel tanks have a capacity of 50,000 liters each, approximately 5 tons when empty and
approximately 63 tons when filled with fuel.
2. The Tank Bund Wall dimension is 25.0m W x 14.5m L x 0.60m H.
3. The tanks shall be positioned with a minimum of 2.0m space at each other.
4. The surveyor will layout the location of the fuel tank area.
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MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
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DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 567 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
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5. Initially, the ground marked perimeter will be cleared from any loose materials, watered, leveled,
and compacted until no signs of settlement are observed. This is to ensure that no undesirable ground
settlement might happen after the tanks are placed on the supporting beams as well as when it is to be
refilled with fuel.
6. The perimeter wall will be 200mm x 400mm x 200mm concrete block with plastered finish both
inside and outside.
7. The concrete base slab shall be a minimum of 100mm thick slab on grade with class C40 on laid
reinforcement 2 layers of steel mesh 10mm ø.
8. The concrete base shall be cured for a minimum of 7 days by covering the surface of the concrete
and keeping it continuously wet, continuous use of fine fog water sprays covering the surface with a
saturated absorptive cover and keeping it continuously wet.
9. Once fully cured, a continuous upstand in the form of a steel I-beam will be assembled for each tank
and in place on top of the concrete base.
10. The outer side of the bund wall will be painted with the color black and yellow alternate diagonal
lines.
7. POSITIONING OF FUEL TANKS
When the area is ready to accommodate the fuel tanks, delivery and positioning will be the next
procedure.
The tanks will be delivered on-site by a trailer truck and shall be positioned using an adequate mobile
crane. Prior to commencing lifting works, the Crane Load Test Certificate shall be checked. The
certificate will be no older than 12 months when arriving on-site and will cover the following:
Ropes (certificates will be identifiable to the specific crane)
Hooks
Slew Brakes
Outriggers and Pads
Boom and Guides
Anti- Two block Device
Load Indicating System
Boom Sheave Wheels Condition
Crane Brakes and Air System
Load test certificate (identifiable to the specific crane).
A brake or other device capable of holding the maximum mass should the power fail, or which is such
that it will automatically prevent the uncontrolled downward movement of the load when the raising
effort is interrupted; and
A limiting device that will automatically arrest the driving effort when:
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The hook or load attachment point of the power-driven lifting machine reaches its highest safe
position, and in the case of a winch-operated lifting machine with a lifting capacity of 5000 kg or more:
the load is greater than the rated mass load of such machine.
8 .POSITIONING CRANE
The area where the crane is to be positioned/set up shall be adequately chosen. Ensure that the
ground is firmly level and stable, the outrigger must be fully extended with appropriate padding.
The lifting area shall be properly barricaded to check the load chart and another necessary documents
such as certificates.
Only trained operator/rigger with certificates shall be allowed to use and perform such type of lifting
works. HSE will inspect the site and confirm site conditions are satisfactory.
9 .POSITIONING OF LOADED TRAILER
Prior to any lifting operation, a final check will be conducted to ensure all the required documents are
at the site and complete.
Through communication with the truck driver and crane operator, the truck will be suitably positioned
to ensure a safe control lift can be achieved.
The load retentions belts will be removed to allow the load to be taken off.
11.LIFTING OPERATION
Once the retention belts were removed and all necessary permits such as Work Permit and Lifting
Permit are secured, lifting operation shall commence.
The Site Engineer shall first check and determine the load to be carried.
Prior to lifting, ensure that the lifting area is unobstructed and free from unauthorized personnel. The
operator shall only perform lifting upon the instruction/signal of the competent rigger.
Carefully lift the first tank and place it on the prepared steel upstand. Once adequately placed on top
of the upstand, installation of bolts to secure the tank on the steel upstand shall be done.
The lifting strap shall be maintained while installing the bolts and shall only be released upon
tightening of all bolted connections and upon the confirmation of the competent rigger.
The lifting and positioning shall continue until all 5 sets of fuel tanks are fully installed.
11. DIESEL SUPPLY
Truck Route
Figure here
Distribution of Diesel
Supervise all deliveries to help avoid spillages, prevent damage to the environment and save valuable
raw materials. Ensure that the secondary containment area is of sufficient size and volume to store all
diesel received within the bunded area. No diesel may be stored outside the bunded area.
Suitable diesel dispensing mechanisms like pumps or taps must be fitted to containers to prevent
spillage.
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The following steps will be implemented prior to scheduling diesel delivery to the diesel storage area:
Check and record the existing tank headspace volumes.
Order only a diesel quantity that is needed to fill the tanks to a maximum of 90% of the total working
volume.
Schedule diesel delivery for daylight hours only; only during emergency situations will diesel be
delivered to the site during hours of darkness; trucks attempting diesel delivery during hours of
darkness will be refused entry into the site unless special permission has been prearranged by the
PMV Manager.
Verify that the spill kit is available at the fuel storage facility.
The following steps will be implemented during the delivery of diesel to the diesel storage area:
Security personnel will stop the delivery truck at the site entrance and inform the Security Supervisor
of the truck’s arrival.
Security personnel will inspect the vehicle for any leaks and verify that a fire extinguisher and driver
PPE are onboard the truck.
Security personnel will direct the truck driver to proceed to the delivery area.
HSES or diesel storage facility in charge will complete a STARRT card form with the unloading crew
Station a fire and spill watch.
Verify all tank fill line anti-siphon valves are open.
The authorized person will remove padlocks from the main fill valve and camlock cap.
The delivery truck driver will connect hoses from the truck to the main fill valve.
Authorized personnel will inspect the hose fittings and verify they are properly connected.
Place drip trays where appropriate.
Verify all diesel tank balance line valves are fully open.
Open the main fill valve.
Start the truck’s fuel transfer pump, open the pump suction valve, and monitor the hose connections
for fuel leaks
Post a spill watch at the overflow sump during the fuel offloading.
Fuel tanks should not be filled above 90% of the total working volume.
After transferring the fuel, close the pump suction valve and the main fill valve.
Place a bucket below the drain valve and slowly open the valve to discharge fuel remaining in the fill
hoses into the bucket.
Disconnect fuel transfer hoses and stow away; secure the main fill inlet with a camlock cap.
Padlock the main fill valve and camlock cap.
Record the fluid level in the fuel storage tank.
The truck driver and facility operator will sign off the check sheet.
Remove drip trays and allow the delivery truck to proceed away from the area.
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Monitor the diesel storage area for 30 minutes after delivery completion to verify fuel spills have not
occurred; verify fuel has not been discharged into the secondary containment; if fuel was discharged
into the secondary containment notify the facility manager immediately.
Clean the area.
12. SAFETY/ENVIRONMENTAL REQUIREMENTS
12.1 ENVIRONMENTAL EDUCATION AND AWARENESS
Ensure that all site personnel has a basic level of environmental awareness training. The contractor
must submit a proposal for this training to the ECO (Environmental Construction Operations) Plans
for approval.
Topics to be covered should include:
What is meant by “environment”?
Why the environment needs to be protected and conserved
How construction activities can impact the environment
What can be done to militate against such impacts?
Awareness of emergency and spills response provisions
Social responsibility during construction, e.g. being considerate to local residents
It is the company’s responsibility to provide no less than 1 hour’s environmental training and to
ensure that the team has sufficient understanding to pass this information onto the construction
staff.
a) Translators are to be used where necessary.
b) The Engineer/ECO should be on hand to explain more difficult/technical issues and to answer
questions.
c) The use of pictures and real-life examples are encouraged as these tend to be more easily
remembered.
d) Use of environmental awareness posters on-site.
e) The need for a ‘clean site’ policy also needs to be explained to the construction workers.
12.2 SECONDARY CONTAINMENT SPECIFICATIONS
Situate all diesel tanks and ancillary equipment within a liquid-tight secondary containment system
like a bund.
The risk of diesel escaping the bund and contaminating the environment will be minimized when the
following are adhered to:
Keep the primary container as low as possible.
Ensure that the walls of the bund are of sufficient height and integrity to avoid leakage.
Ensure that all diesel dispensing mechanisms, valves, filters, or other ancillary equipment are kept
inside the bunded area to avoid spills outside the secondary containment.
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Leave sufficient space, a minimum of 750mm between the container and the bund wall, and 600mm
between the container and the base of the bunding, to allow access for external inspection.
Do not place one container above another.
The bunding must be impermeable to liquids.
There must be no direct outlet from the bunded area. No pipework may pass through the wall of the
bund.
The bunded area may not be discharged to any drain, sewer, or watercourse or be discharged into
the yard or unprotected soil.
The bunded area must be roofed to ensure that rainwater does not collect inside the bunded area.
Rainwater will reduce the volume inside the bund, making the bunding ineffective.
Do not use bunds to store materials or wastes, as this will reduce the capacity.
12.3 DEALING WITH SPILLS
It is a priority to undertake all measures to prevent spills, to ensure that diesel is stored and
dispensed according to the specifications discussed above, and to use drip trays when working with
diesel.
In the event of a spill, keep a stock of absorbent materials like sand or commercial products on-site
to deal with spillages and train staff in their use. Make use of spill kits. Ensure that relevant staff is
trained to use spill kits effectively.
Excavate contaminated soil or other contaminated material and place the contaminated material in
impermeable bags for responsible disposal at a suitable landfill. Under no circumstances may diesel
spills be left or covered. Deal with spills immediately.
If a spill occurs, immediate action should be taken to contain the diesel to prevent it from entering
any drains or watercourses. Do not hose the spillage down or use any detergents.
Notify the Environmental Officer appointed to the project of any spill and complete an Environmental
Incident Report Sheet.
Fire Extinguishers: Dry chemical powder and foam fire extinguishers are to be placed 5 meters away
from the storage tank and to be installed inside industrial-type boxes.
13. MAINTENANCE
Inspect all bunds, tanks, and pipework regularly for signs of damage, at least weekly. To ensure that
the bund retains its integrity, repair any defects in the Bund Wall promptly. Deal with damage to diesel
tanks immediately.
Any accumulated oil, diesel, debris, or sand must be removed and disposed of in an appropriate
manner to a suitable landfill site.
Do not cover the base of the secondary containment area with sand or any other material. This will
hide diesel spills and make inspections difficult. Do not undertake any maintenance work involving
diesel on unprotected soil; always use a drip tray to contain any spillages.
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14.RISK ASSESSMENT
Please refer to the attached document in Appendix B.
15.PERMIT AND LICENSING REQUIREMENTS
Please refer to the attached Permit to Work on Appendix C.
16.DRAWINGS, DIAGRAMS, AND MAPS
Please refer to the attached document in Appendix A.
17.PRE-START SAFETY BRIEFING ARRANGEMENTS
Refer to Risk Assessment on Appendix B.
18. PROTECTIVE AND SAFETY EQUIPMENT
All workers Involved shall be equipped with adequate PPE as stated below:
a. Safety Helmet with Company Logo
b. Safety Boots
c. High Visibility Vest
d. Safety Goggles
e. Hand Gloves
f. Coveralls
g. Respiratory Mask
h. Safety Harness
19. INFORMATION TO PERSONNEL
a. Safety Induction
b. Job training
c. Superintendents Notices/Memos
d. Toolbox talks
e. STARRT Card
20. SPECIAL SAFETY REQUIREMENTS
a. All necessary personal/protective equipment (PPE), as well as harness, be provided.
b. Banksman, wearing distinctive vests, shall be assigned to help operators maneuver their equipment.
c. The equipment operators shall possess the required licenses and certificates.
d. Generated dust shall be controlled by periodic water spraying.
e. The project safety officer is responsible along with the project zone site engineer for ensuring that
all operations are carried out with due regard to the safety of all project personnel & property.
f. All working activity shall comply with client safety procedure.
g. First Aid Material.
h. General management of protection/operation hazards are to be observed.
i. In case of working at night, please refer to Method Statement for Night Works
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21. ENVIRONMENT AND QUALITY ISSUES
1. Precautionary Measures
All precautionary measures shall be briefed to all workers prior to commencing the activity.
2. Disposal Requirements
All waste shall be disposed of as per Environmental Compliance & Management Plan and as per
government-approved disposal areas.
3. Quality Assurance Requirements Table
Refer to Project Quality Plan
22. ATTACHMENTS
1. Appendices
Appendix A: Risk Assessment
Appendix B: Permit to Work
Appendix C: Organization Structure
Appendix D: Directional, Information & Warning Signs (Photos)
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METHOD STATEMENT FOR
GRP INSTALLATION
SR. EFFECTIVE REV. MSS MANAGER MSS PROJECT CLIENT
CLIENT QA/QC
NO. DATE NO. QA/QC MANAGER SUPERVISOR
GRP INSTALLATION
1. PURPOSE
This method statement for GRP formalizes the requirements for installation and testing of GRP (Glass
Reinforced Plastic) pipes & fittings for the underground external stormwater networks.
The specifications, procedures, and guidelines contained in this method statement specify the
technical requirements to be followed and also act as a reference to clearly establish defined
standards for work assessment. Moreover, this document shall provide guidelines to check that
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specified materials are installed and agreed procedures are implemented during the execution of work
and to define the responsibilities for controlling the execution.
2. SCOPE
This method statement describes the sequence of activities involved in the installation and testing of
GRP pipes and fittings for the stormwater network as per the requirements derived from the scope of
work, contract specifications, codes, and standards of the project.
3. DEFINITIONS
Client – xxxxxxxxx
Project Management-Construction Management (PM-CM) – xxxxxx
Construction Supervision Consultant (CSC) – xxxxx
Main Contractor – xxxxx
Supplier/Vendor – Seller of material as defined in the project specification
4. REFERENCES
Approved material submittals
Approved shop drawings
Project Specifications
5. ABBREVIATIONS
HSE-Health Safety and Environment
QA/QC-Quality Assurance and Quality Control
MST-Method Statement
RA-Risk Assessment
ITP-Inspection and Test Plan
PQP-Project Quality Plan
INR-Inspection Request
PPE-Personnel Protective Equipment
STARRT-Safety Task Analysis Risk Reduction Talk
6. RESPONSIBILITIES
6.A. General
1. Project Manager (MEP) will be responsible to manage, executing, complete and handover the
construction activities within approved budgets and resources in compliance with Project
Requirements as specified in Project Specifications. He will be overall in charge of implementing the
Method Statement for GRP installation in accordance with QA/QC and HSE requirements.
2. Construction Manager will be responsible for managing construction activities and will lead and
communicate with site Supervision, Subcontractors, and Vendors to assist them in working to the
Project Schedule by conforming to QA/QC and HSE requirements at site.
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3. HSE Manager will be responsible for planning, coordinating, and implementing issues and
directives within the organization. He ensures safe environmental working conditions for all
employees.
4. QA/QC Manager will be responsible for supporting the project team in implementing and
maintaining Quality Management System for the project through POP, ITP, MST, and Procedures in
compliance with Project specifications, Codes, and Standards.
5. HSE Officer will ensure enforcement of safety procedures in accordance with the approved HSE
Plan. Will be closely monitoring the site engineer’s strict implementation of the MST and Risk
Assessment, the use of proper tools and equipment to maintain safety, certifications of equipment
and their adherence to safety regulations, reporting of any unsafe work or stopping work that does
not comply with HSE procedures.
6. Site Engineer will be responsible for carrying out all construction-related activities with compliance
to HSE and QAQC requirements as per contract specifications, drawings/documents, codes, and
standards.
7. QA/QC Engineer will be responsible for conducting inspections as per PQP.
8. Supervisor/Foreman will be responsible for coordinating all works and workers related to the job.
9. Electrician / other tradesmen will be responsible for assisting his superiors during all construction
work-related activities following HSE and QAQC requirements.
10. Store In-charge receives and inspects all incoming materials and reconciles with documents;
processes and distributes documentation; reports, documents and tracks damages and
discrepancies.
11. Security guards will be clearly visible, vigilant, respond quickly and correctly during the crisis,
observe and report, check and monitor, maintain order among workers, and offer safety warnings
and tips.
7. LIST OF SUBCONTRACTORS
Subcontractors for MEP: xxxx
8. TRANSPORTATION, HANDLING AND STORAGE
Ensure that flatbed trailers are used for transporting the GRP pipes and that the trailer’s bed is free
from nails/sharp objects.
Pipes should be uniformly supported throughout the length by flat timber placed beneath each pipe
layer with spacing not greater than 4 meters.
Chock the pipe with wooden wedges to maintain stability and operation. Ensure no pipe to pipe
contact (in between each layer) to avoid abrasion during transit.
Stack height should not exceed 2.6 meters.
While in transit, strap the pipes to the vehicle over the support points using pliable straps or nylon
ropes. Never use steel cable or chain without having adequate padding to protect the pipes from
abrasion.
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While loading and offloading the pipes, do not drop impact or bump the pipe particularly at the pipe
ends.
While loading and offloading the pipes by forklift/crane, fork and steel ropes must be protected with
rubber pads to avoid their direct contact with pipes to prevent damages.
When loading/offloading the single pipe, use pliable straps, slings, or ropes to lift with two support
points placed at an equal distance to handle the pipe easily.
While in transit, ensure that the maximum diametrical deflection must not exceed the value as shown
in the below table:
Maximum Deflection During Transit
Stiffness (SN) Maximum Deflection (%)
1250 3.0
2500 2.5
5000 2.0
10,000 1.5
Following timber sizes should be used to support the pipes
Size Pipe Diameter
100 x 100 mm 1000 mm and above
75 x 75 mm 600 to 900 mm
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50 x 75 mm 500 d below
9.HANDLING & STORAGE:
Ensure that the storage surface is clean and clear from rocks or any other solid objects.
Pipes should be stored separately according to their class and diameters
Stacked height should be stacked in layers with each pipes socket placed at alternate ends.
Pipes should be placed on flat timber supports at a maximum of 4 meters spacing with wooden
wedges to prevent sliding of the pipes from the stack.
While shifting the GRP product by forklift/crane, metal slings, chains, and forks do not come into direct
contact with the product.
Fittings are normally stored on top of the pallets. Direct contact between products should be
prevented in the storage area.
Spool should be stored in a flat area. Ensure that wooden seating beneath the spool is provided as
required. Also, ensure that contact between products is avoided.
Care must be taken that the storage is leveled, firm, and clear of rocks or solid objects that might
damage the pipes and spools. If it is necessary to stack pipes, it is best to stack on flat timber supports
and a maximum of 4 meters spacing. The maximum stack height is approximately 2.8 meters. Stacking
of pipes from dia.1500mm up to dia. 4000mm is not recommended. This height is limited for safety
purposes and to avoid excessive load on the pipe during storage.
Ensure suitable supports are used for example wooden beams, measuring 10 x 5cm. to avoid damage
to machined pipe ends. Stacking should be undertaken with care. It is recommended to protect
machined ends for example by polyethylene-covered straw mats or polyethylene netting. The socket
and spigot end must not touch each other.
The pipe can be stacked economically by alternating the spigot with the socket in order to avoid
bending of the pipes, the beams should be laid directly above each other in a vertical line.
Wooden wedges which are used in order to prevent the pipe stack from sliding should be placed on
both sides of the stack on the timber bearers.
While shifting the GRP/GRE product by forklift/crane, metal slings, chains, and forks must not come
into direct contact with the product.
Fittings are normally stored on top of the pallet. Direct contact between products should be prevented
in the storage area.
Spools should be stored in a flat area. Ensure that wooden seating beneath the spool is provided as
required. Also, ensure that contact between products is avoided
DN 80-400 450-600 700-800 900-1400 >_1500
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 579 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
Layers in stockpile 5 4 3 2 1
H max. < 2m < 2.4m < 2.4m <2.8m
Important:
The pipe has to be segregated based on the same diameter, and pressure classes, and thickness since
two pipes of the same diameter can be of different pressure classes and hence have to be stored
separately with a tag identifying each pile
If the product is stacked too high for long storage periods (6-12 months) and subjected to high
temperature, the supports may cause flattening. It is recommended that the product (in particular
machine parts) be stored under tarpaulins or (white) polyethylene sheeting.
Pipe stacks should have side supports or blocks to roll or slip of the stack during stormy weather.
The pipe stack should have side supports or blocks to prevent the rolling or slipping of the stack during
stormy weather.
Unprotected flange faces should never be placed directly on the ground or on concrete floors.
10.STORAGE OF JOINTING MATERIAL:
Store gaskets, adhesives kits, resins, hardeners woven roving, lubricants, and consumable in their
original packaging in AC controlled room between 20° – 30°C. Keep dry, away from frost, direct
sunlight, and ozone.
Observe the self-life of the adhesive and resins (For the resin-The shelf life is 3 months from the date
of shipment from FPI Factory to the site). It is preferable to order these as required, however, it is
recommended to follow MSDS for better storage.
12.HANDLING OF NESTED PIPES:
Always lift the nested bundle using at least two pliable straps limitations, if any for spacing between
straps and lifting locations will be specified for each project. Ensure that the lifting slings have
sufficient capacity for the bundle weight. This may be calculated from the approximate pipe weights.
It is recommended to use soft liquid or rubber inside the nesting pipe to make more smoothen the
nesting process.
There should be a minimum gap/size difference between 2 pipes with 200mm.
The lifting boom should be covered with corrugated paper or it should be laminated
The nested pipe is usually being stored in the transport packaging. Stacking of these packages should
not occur unless specified otherwise.
Nested pipe bundled can only be safely transported in the original transport packaging. Special
requirements, if any, for support, configuration, and/or strapping to the vehicle will be specified for
each project.
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Package removal and de-nesting of the inside pipe(s) is best accomplished at a de-nesting Station.
Typically, this consists of three or for-fixed cradles to fit the outside diameter of the largest pipe of the
bundle. Inside pipes starting with the smallest size may always be removed by lifting slightly with an
inserted padded boom to suspend the section and carefully move it out of the bundle without
touching the other pipes.
When weight, length, and /or equipment limitations preclude the use of this method, the procedure
for sliding the inside pipe(s) out of the bundle will be recommended for each project
There should be proper attention or care to be taken while de-nesting pipes and pipes should not be
de-nested on from the trailer bed directly.
To ensure that the boom should be laminated in order to avoid direct damage.
12. MATERIAL INSPECTION
For materials to be inspected after receiving at the site, the following points are to be followed:
Each material item shall be allotted a distinct and separate reference number and mentioned on the
material requisition. Make sure that material is approved/examined by the consultant and QA/QC and
associated documents/test certificates are approved.
The Store In-charge shall ensure that all approved supplies be delivered to the site as per the approved
material submittal; with the manufacturer’s seals, labels, or other proof of origin intact. These labels
and seals shall not be removed until the material is required for use and shall be retained for
inspection by the consultant and QA/QC.
Store In-charge shall initiate material inspection for all incoming material to QA/QC and the material
shall be inspected against reference documents and as per approved material submittal. Moreover,
the physical condition of the material shall be checked. Afterward, an INR shall be raised by QA/QC to
the consultant and inspection will be carried out by the consultant.
Materials, which do not conform to the given specification/approved material submittal, shall be
rejected. Any discrepancy or damages will be notified and reported for further action.
For any materials inspection (especially pipes, fittings, other accessories), the items shall be segregated
as per their type/sizes and placed items separately in racks or on different pallets.
Each rack/pallet shall have an identification posted on a laminated paper with the description of the
items clearly written on it.
There shall be appropriate spaces between the pallets so that the engineer/inspector can freely go
around them and inspect the materials thoroughly.
Staking the materials all over each other & in one corner is strictly not allowed.
All items shall be kept in a protective environment and shall not be kept directly on the floor; they shall
have wooden pallets underneath them.
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13. RESOURCES
13.A. TOOLS AND EQUIPMENT
Tools
a. Pipe fitter standard toolbox
b. Chain Cutter, Cutting ring
c. Chain block
d. Come-Along-Jack (cap. 1.5 Ton)
e. Wooden Pushers Sprit Level
f. Steel clamps with rubber liner and accessories
g. 4″X4″ Timbers
h. Shovels
i. Wooden Plank
j. Wooden spacer (16mm width)
k. Working gloves and goggles
I. Paintbrush 4″ and 6″
m. Rags
n. Marker
Note:
All testing equipment and measuring tools to be used shall have valid calibration certificates prior to
usage.
All lifting equipment and machines shall be 3rd party certified with valid certificates.
13.B. MATERIALS
GRP Pipes and Fitting as per approved material submittal
Geotextile
Warning tape
Double bell coupling
Gasket
Note:
Material shall be used after being approved by Approved Material Submittals.
All material to be used shall conform to the Project Specification and Authorities regulations (where
required).
13.C. LIST OF MANPOWER
Construction Manager
Pipe installers
QA/QC Engineer
Helpers
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HSE Officer
Mobile Crane Operator
Site Engineer
Trailer Driver
Supervisor
Forklift Driver
Foreman
Riggers
14. MOBILIZATION
14.A PREPARATION AND PLANNING
The contractor shall ensure that all gate passes, permits, tools, materials for safety precautions,
manpower, and equipment are available before commencement of work.
The site team shall make sure that access roads are always clear from any obstruction and the site is
always accessible.
14.B. SITE CLEARANCE
Before commencing the work, the area shall be cleared of all debris, materials, or other obstructions.
14.C. TRAFFIC MANAGEMENT
The Site Team with the assistance of the Safety Officers shall coordinate logistics and materials
movement through the site following the direction and road signs displayed on site.
The required diversion routes shall be marked on drawings including the required traffic signs.
The Work Permits and Operator Certificates shall be compiled and filed for reference by authorized
personnel.
Temporary traffic signs, barriers, and flagmen will be deployed to control traffic flow in accordance
with and Traffic Management of the HSE Plan.
At the end of each ramp, there will be a transition area to give the driver the opportunity to watch
the access roads before joining thereto.
14.D. PRE-CONSTRUCTION SAFETY MEETINGS:
The meeting shall be scheduled prior to the beginning of the work and before any Subcontractor
starts on the project.
Safety awareness meetings will be conducted every working day morning/every other Day to brief
the workforce on the safety prevention measures. The equipment check for safety shall be recorded/
documented during the daily Safety Awareness Meeting.
Traffic safety will be discussed to emphasize these meetings.
Each worker will be instructed to follow specific safety requirements related to his trade. They will be
required to follow installed safety signs, observe barricades and use PPEs.
The contractor safety officer will perform hazard risk analysis by identifying all steps, hazards
identified in those steps, with a focus on the relationship between the work task, the tools, and the
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work environment. After identifying uncontrolled hazards; The contractor will take steps to eliminate
or reduce them to an acceptable risk level.
General Contractual Safety, Health, and Environmental requirements:
Roles of the contractor, subcontractors, authorized representatives, and all project workers.
Accident reporting requirements.
Specific details of the work to be performed along with the use of personal protective equipment.
Emergency procedure.
14.E. OPERATING PROCEDURES:
A site investigation has to be carried out to develop safety precautions and measures prior to the
commencement of the work. After such investigation, relevant signboards will be displayed and
barricades will be installed where and as necessary, such as but not limited to the following:
Relevant information, advanced signs, warning, and mandatory signs will be placed as required.
Radio Communication system would be used where normal communication is impossible.
After completion of the work, safety cones and barricades have to be removed accordingly.
15. METHODOLOGY
15.1 PRE-INSTALLATION
All necessary work permits shall be obtained prior to the commencement of any activity at the site
and shall remain valid throughout the entire duration of the operation.
Site interface permits to be taken from other contractors before placing pipe at tie-in point to
reconfirm IL and coordinates.
All activities for earthwork, trench excavation, pipe bedding in trenches, initial backfilling and final
backfilling, laying of marker tapes, and all associated jobs relates to civil shall be done by the civil
contractor.
Dewatering shall be added if the excavation level is lower than the water table. Dewatering shall be
performed by the civil contractor.
Check & verify that the civil work is completed in compliance with all requirements for installation as
per approved shop drawing and handed over for mechanical works. Joint inspection of the location
shall be carried out by the consultant & contractor before releasing the excavated trench for
installation works.
For the waterlogged area, gabbro material as gravel shall be used.
Prior to the commencement of work, inspect areas and access to confirm that the site is ready to
commence the work and coordinate with other trades and subcontractors.
Please refer attachment checklist for site readiness.
Ensure that proper and dry trench beddings are placed.
Ensure that gridlines, reference levels, etc. are marked.
Ensure trenches are free from obstruction, rocks, and other debris prior to laying pipes.
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All relevant documentation approved shop drawings, and material applicable to a particular section
of works will be checked by Site Engineer prior to commencement of work.
Ensure that material received is in compliance with the Project Specifications/Authorities Regulations
and is approved.
Ensure that all required materials and accessories are delivered, inspected, and approved by the
Consultant and are readily available at the site to carry out the work.
The site engineer and his Supervisor/Foremen will carry out a site survey and mark the route of
piping as per approved shop drawings. In the event of any discrepancies or difficulties in executing
the work, these shall be brought to the notice of the Construction Manager for corrective action.
All relevant documentation (including method statement for GRP installation and risk assessment are
approved, obtain necessary work permits, fill up STARRT cards after completion of daily toolbox talk),
will be checked by Site Engineer prior to commencement of work.
The Site Engineer/Site Supervisor will give necessary instructions to tradesmen (Plumbers/pipe
installers) and provide necessary approved construction/shop drawings.
The Site Engineer/Site Foreman will check that proper tools and equipment are available to carry out
the work and are in compliance with contract specifications.
The Site Engineer will explain to his team about HSE precautions to be observed.
Trial pits shall be carried out for all existing services prior to any excavation activities.
Cut-off walls shall be formed in granular bedding and surround to pipes to prevent the bedding from
acting as a subsoil drain. Cut-walls shall be provided at a maximum spacing of 40m with one at each
manhole and structure and at least one cut-off wall between two adjacent manholes and structures.
Cut-off walls shall be made from an impervious fine-grained clay mixture, prepared with the addition
of water where necessary, to suitable trench spoil of available, or imported. Concrete cut-off walls
shall be Grade 20 SRC concrete. Cut-off walls shall be installed across the full cross-section of the
granular bedding material and shall be at least 300mm wide along the axis of the pipeline.
16. INSTALLATION STEPS:
16.1 SETTING OUT
Pipe centerlines coordinates are provided as part of the approved shop drawings together with
pipelines level. Meanwhile, as the primary out is carried out during excavation of trench of which its
survey marks could be removed during excavation works, the Glass Reinforced pipe will be installed
at trench centerline, unless otherwise shown in the shop drawings as might be the case according to
actual site conditions.
However, stormwater pipeline strings i.e. from manhole to manhole will be marked by setting out
manholes centerline and pipe bottom level by short steel bars firmly placed in the natural rock by
means of drilling, hammering, or mortar for every manhole and 5m of pipelines, as well as at every
slope change if required. Setting out a survey will be checked by the engineer and surveyor.
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As-built excavated trench width and formation level are jointly surveyed by MP contractor and Main
contractor and recorded as part of excavated trench hand over the procedure which shall involve a
joint survey record for the trench bottom level, pipe centerline, and trench coordinates as well as
status of groundwater: the same shall be verified against pipeline route and layout shop drawings,
before releasing the area being surveyed for further works.
The top of the pipe level shall be marked by surveyors using the string wire and timber’/steel braces;
at the same time and according to pipe diameter and ground conditions, aggregate bed and surround
top levels will be marked by spray paint on trench sidewalls.
Pipe levels will be reviewed with as-built trench level and cross-checked by MEP subcontractor and
main contractors engineers representative prior to/and during the course of construction made in
stages, including:
Bedding material placement (and compaction, if needed)
Pipe installation
Surround material placement (and compaction, if needed)
Further, the following locations levels and coordinates have to be mutually checked and marked
carefully prior to installation, subject to the engineer’s acceptance or instructions.
Each pipe/joint level and coordinate
Change in gradient (slope), if any
Manholes centerlines and offset, if any.
16.2 DEWATERING
If the final excavation level is lower than the groundwater level, the dewatering will be performed to
make the dry condition at the final excavation level as the submitted method statement for
dewatering work. During the excavation, a submersible pump will be used to discharge the water to
the approved discharge location.
17. TRENCH SPECIFICATIONS
17.1 THE TRENCH:
The trench excavation should not be too far ahead of the pipe laying team to ensure better control of
the trench and for safety reasons. The excavated soil should be placed on one side of the trench
leaving the other side, clear for equipment and pipe handling. If the trench consists of various layers
of soil, these should be placed separately in order to use the stone-free granular material for backfill.
17.2 MINIMUM TRENCH WIDTH:
The trench width must be maintained within certain limits. A very wide trench will increase the
volume of backfill material required, and compaction labor and effort. A very narrow trench will
render laying, handling, and jointing of pipes, as well as compaction of side, backfill difficult.
Note:
► In poor native soil conditions and depending on pipe stiffness and burial depth, a wide trench (up
to 4XDN) might be required.
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► The distance between the pipe and the trench wall should be at least 10cms wider than the width
of the equipment used for compaction of the backfill material.
18.PARALLEL PIPES INSTALLED IN THE SAME TRENCH:
Where two or more pipes are installed in parallel in the same trench, the following minimum distance
should be maintained in order to allow for sufficient room to place and compact the backfill material
under the pipe haunches, for all the pipes in the trench.
The distance between the pipes should be at least 10 cm wider than the width of the equipment used
for compaction of the backfill material. Where pipes are of the same or different diameters are
installed in the same trench, a minimum spacing equal to (DN pipe a + DN pipe b)/4, but not smaller
than 300mm is required.
19. TRENCH DEPTH:
20. MINIMUM COVER DEPTH:
Generally, the cover depth of the pipe is specified by the design Engineer. When there is no traffic load
over the pipe, the minimum burial depth is 0.6 m. in the presence of traffic loads, a minimum cover
above the pipes shall always be maintained as follows for all stiffness classes.
Load Type Traffic Wheel Loads Minimum Burial Depth
AASHTO 72 KN 16,000 lbs 1m
BS 153 HA (C) 90 KN 20,000 lbs 1.5m
ATV LKW 12 (C) 40 KN 9,000 lbs 1m
ATV SLW 30 (C) 50 KN 11,000 lbs 1m
TV SLW 60 (C) 100 KN 22,000 lbs 1.5m
21. HIGH WATER TABLE:
In the case of a high groundwater table, a minimum cover depth equal to 0.75 times the pipe diameter
of granular soil (minimum dry density of 1300 kg/m3) must be provided to prevent pipes from floating.
Always ensure that this minimum cover is available before turning off dewatering systems.
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22. MAXIMUM COVER HEIGHT:
The maximum cover height depends on the pipe stiffness, type of installation, backfill material, and its
compaction, as well as native soil conditions.
23. LOWERING THE PIPE INTO THE TRENCH:
Handloading should be executed by at least two men. It is recommended that the weight carried by
one man do not exceed 30 kg. Pipes weighing up to 175 kg can be lowered by means of two ropes. The
ropes must be anchored to stakes.
24. LOWERING WITH ROPES
Mechanical lowering is used for larger diameter pipes, especially when combined with pipe assembly
in the trench. Two straps or slings can be used from an excavator boom if no separate lifting
equipment is available.
25. PIPE JOINING
Pipe joining will consist of the following steps:
The rubber ring needs to be installed on both grooves of the double bell coupler while the double bell
coupler is still at ground level
One double bell coupler needs to be inserted on each pipe (ie. one side only) while the pipe is at
ground level, before being lifted to be laid inside trenches.
26. RUBBER RING ASSEMBLY:
The rubber ring should be fitted into the coupling when the coupling is in a horizontal position, as
shown in Figure.
Clean the grooves of the double bell coupler and rubber gaskets with a brush or rag. Ensure that these
areas are totally free of dust or any other dirt. In dusty and windy weather conditions, the area where
the rubber ring assembly is taking place needs to be protected from all sides to avoid dust, sand, and
dirt. If such protection cannot be provided, the work shall be stopped.
Insert the gasket into the groove, leaving enough loops to ensure a uniform distribution of the stress
along the gasket length. Then, with uniform pressure, push each loop into the groove, Check that the
ring is uniformly fitted into the groove of coupling.
Apply lubricant on the outer surface of the rubber ring. After lubricating, ensure to keep the coupling
and rubber ring clean and free from sand particles.
27. MOUNTING THE COUPLING ONTO THE PIPE:
The below step should be followed while the pipe P1 is still at ground level and properly supported
with temporary wooden supports. Clean the grooves of the double bell coupler and rubber gaskets
with a brush or rag.
Clean the dust and foreign material from the outer surface of the pipe spigot with a firm brush or rag
and ensure the pipe spigot has a smooth and glossy appearance.
Apply vegetable base soap on the outer surface of the pipe spigot.
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Fix a pipe installation clamp on the home line, which will also act as a stopper to stop the coupler
exactly on the home line.
Hold the coupler with a sling wrapped around it. The coupler shall be held until it has been fully
mounted on the pipe spigot.
The coupler is mounted on the spigot using come-along- jacks which will pull the coupler towards the
pipe. Keep the installation clamp in its position.
The pipe with coupler mounted is then ready to be lifted by a crane and laid inside the trench before
jointing it to another pipe.
28. PIPE ASSEMBLY:
In the following steps, it is assumed that previously a pipe along with its mounted Coupler has been
already laid with the pipe support clamps.
Place temporary nylon or pressure-treated wooden spacers 16mm thick at 12, 3, 6, and 9 o’clock
positions on the pipe edge. These spacers will ensure that the gap Of 16mm between the two pipes is
maintained as specified by the manufacturer.
Pipe P2 with its mounted coupler (coupler mounted as described in the above steps) Is carefully held
by a crane and position along the final axis of the line before joining it to pipe P1 using P1 ‘s coupler.
(Note: P2’s coupler would be used for installing a pipe P3 for example). Ensure that the two pipes are
aligned Horizontally & vertically before joining them.
Make sure that pipes P1 & P2 still have the installation clamps clamped over them.
Clean the outer surface of the pipe spigot end with a firm brush or rag. Ensure that the area is totally
free of foreign particles.
Apply vegetable-based soap on the outer surface of the pipe spigot.
Attach pullers to the pipe installation clamp of pipe P1 to the pipe installation clamp of P2. Pull the
pipe by jacking the pullers until the edge of the coupling reaches the home line of the new pipe. At this
stage, the edge of the new pipe would be touching the wooden spacers.
Loosen and detach the pullers.
Install the support clamp on both ends of pipe P2.
The current setup is ready for installing pipe P3 & Jointing it to pipe P2 etc.
All spacers must be removed before hydro testing and commissioning.
Laying of pipes in Trench Bedding
All civil-related works are mentioned here for reference only. Civil works shall be performed by the civil
contractor.
The laying of drainage pipes in trenches shall be in accordance with the relevant provisions of project
specification/ manufacturer’s recommendations.
29. GENERAL
GRP pipe shall be installed in trenches that shall not exceed the maximum trench width at 300mm
above the crown of the pipe as shown in Table 2.1 of Part 2 of Section 8.
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Pipe bedding shall be provided as shown on the Drawings or stated in the approved methods
statement.
Pipe bedding shall be well compacted and shall completely fill the whole width of the trench
excavated.
Wet conditions: In the wet ground, sloppy working conditions can be alleviated by first placing a layer
of hard granular material, or by de-watering the area in and around the trench. If patches of ground
area are so wet that there is a risk of subsidence and possible damage to sections of pipeline, these
areas are to be consolidated by the addition of fill material. (Details shall be included in the shop
drawings).
Any over-excavation adjacent to a structure or beneath the formation level of a pipeline, either to be
constructed under the Contract or in a future contract, shall be backfilled with Grade 20 SRC concrete.
In case that the trench width exceeds the limits, the contractor shall provide plain or reinforced
concrete cradles and/or reinforced concrete arches to the requirement shown in the drawing and to
the approval of the Engineer at no additional cost
Table 2.1 – Minimum pipe trench width at 300mm above pipe crown:
Nominal Bore mm Maximum Trench Width mm Nominal Bore mm Maximum Trench Width mm
100 550 600 1350
150 600 800 1550
200 800 1000 2000
300 900 1200 2300
400 1000 1400 2500
500 1250 1500 2700
Granular bedding material for rigid pipes shall conform with the following requirements:
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DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 590 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
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Shall be clean gravel or broken stone from a source approved by the Engineer. Gabbro shall be used in
waterlogged ground.
The granular material size shall be according to the following grading limits given in Table 2.2
Table 2.2 – Gravel size grading limits
Nominal Bore BS Sieve Size, 100% Passing By Weight- Dry BS Sieve Size, 100% Passing By Weight- Wet
mm Condition Condition
100 & 150 14 20
200-500 20 37.5
600-800 37.5 50
1000 & above 37.5 50
Bedding for pipes shall be constructed by spreading and compacting granular bedding material over
the whole width of the pipe trench.
Bedding material shall be in accordance with the project specifications unless otherwise specified.
Nominal single-sized aggregate and graded aggregate shall comply with Table No. 4 of BS 882.
Sand for bedding material shall comply with the relevant provisions of BS 882.
Bedding systems other than those specified in this clause may be allowed upon approval of the
Engineer or as recommended by the pipe manufacturer.
Where socketed pipes are required to be laid on a granular or sand bed, or directly on a trench
bottom, joint holes shall be formed in the bedding material or final excavated surface to ensure that
each pipe is uniformly supported throughout the length of its barrel and to enable the joint to make.
Pipes shall be laid on setting blocks only where a concrete bed or cradle is used and is required by
approved drawings and project specifications.
Where pipes are required to be bedded directly on the trench bottom, the final excavated surface shall
be trimmed and leveled to provide even bedding for the pipeline and shall be free from all extraneous
matter that may damage the pipe, pipe coating, or sleeving. Where rock is encountered, the trench
shall be cut at least 150 mm deeper than other ground and made up with well compacted selected fill
material.
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No protective cap, disc, or other appliance on the end of a pipe or fitting shall be removed
permanently until the pipe or fitting which it protects is about to be jointed. Pipes and fittings,
including any lining or sheathing, shall be examined for damage and the joint surfaces and components
shall be cleaned immediately before laying.
Suitable measures shall be taken to prevent soil or other material from entering pipes and to anchor
each pipe to prevent flotation or other movements before the works are complete.
Where pipeline marker tape is specified in approved drawings/specifications, it shall be laid between
100 mm and 300 mm above the pipe.
Marker tape wording and color shall be in accordance with project requirements. For foul water red
color tape.
30. PROTECTIVE COATINGS
Coatings, sheathings, or wrappings shall be examined for damage, repaired where necessary, and
made continuous before trench excavations are backfilled.
31. BACKFILLING
Backfilling shall, wherever practicable, be undertaken immediately after the specified operations
preceding it have been completed. Backfilling shall not, however, be commenced until the parts of the
works to be covered have achieved a strength sufficient to withstand all loading imposed thereon.
Suitable material shall be used for backfilling. All required tests shall be performed prior to bedding
surround / backfilling
Backfilling around existing structures shall be undertaken in such a manner as to avoid uneven loading
or damage.
Selected fill material for pipe surround shall be placed in a layer of not greater than 150 mm
compacted thickness until the fill has been carried up at least 300 mm above the top of the pipe.
Where the excavations have been supported and the supports are to be removed, these, where
practicable, shall be withdrawn progressively as backfilling proceeds in such a manner as to minimize
the danger of collapse. All voids formed behind the supports shall be carefully filled and compacted.
All safety measures shall be taken during excavation, bedding, compaction, and backfilling.
An open trench will be barricaded by warning tape. A warning sign shall be in place i.e. “Danger”
“Deep Excavation” “Keep Away” “Do Not Enter” “Work Under Progress” etc. Trench barricade
requirement shall not be limited to warning tape, adequate barricade to be provided to suit site
conditions and area.
After completion of backfilling the pipe trench all warning signage, warning tape shall be removed and
the area will be cleaned.
Geotextile filter membrane shall be placed in the trench after formation level.
Concrete surround shall be provided around the pipe if the minimum cover depth is less than 1200
mm.
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Note: For the GRP pipes it is required to maintain the level to achieve the required earth cover to be
1200 mm. Furthermore, this will be mentioned in the shop drawing.
32. INSTALLATION PROCEDURE FOR UNDERGROUND PIPING:
The laying/lowering of pipes shall be performed according to the manufacturer’s recommendations,
and project specifications.
The trench will be made clear from any debris or any sharp object before laying the pipe in. The trench
bottom will be level to provide uniform bearing and support of pipes.
A trench survey will be done for ensuring the required pipe elevation as per approved drawings.
Lower the pipes and fittings into the trench with the crane or any suitable lifting/lowering machinery
or manually depending upon the weight, size, and length of pipe. As per approved material and
specification, any external treatment or protection (sleeves, etc) are not applicable.
Wire rope or any metallic lifting sling will not be in direct contact with vitrified clay pipe while lifting or
lowering into the trench. Cotton Jute or soft rubber material will be wrapped to avoid damage to the
pipe at the place where the sling will tie for lifting the pipe.
Care shall be taken to avoid damage to pipes during lowering into the trench.
Care should be taken in lowering the pipe into the trench to prevent damaging the joint material or
disturbing trench conditions. Never allow the pipe to be damaged along the ground or even at the
trench bottom.
The pipe shall be laid in the upstream direction with the bell end laid upstream.
Make/dig the pit (hole) in the soil under each pipe socket (bell) for firmly resting pipe barrel on the
trench bottom or bedding material so that load is supported by the pipe barrel and not the pipe
socket.
Connect/Join the pipe and fitting ensuring it invert elevation is as per the latest approved shop
drawings. Please refer section jointing procedure of this method statement.
For jointing methods, the manufacturer’s recommendation shall be followed where applicable.
Pipe passing through the concrete/wall shall be installed in the sleeve. Sleeve material will be as per
approved material submittals. Pipe sleeve diameter to be 13 mm larger than the outside diameter of
the pipe.
If required to prevent misalignment, underground piping shall be stabilized and secured as per
approved drawings or by thrust block at intervals, every branch, and every change of direction as
specified in the specification or drawings.
Protective caps shall be removed from pipes and fittings end prior to making joints and at every end of
the working day, pipes ends will be covered or will close with end caps.
After installation check for correct leveling, position, alignment, straightness, and required slope as per
International Plumbing Code.
Installation inspection will be offered for the part or complete portion of the entire underground
piping. Air Testing Inspection will be offered after approval of installation.
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Both inspections will be independent.
Piping will be backfilled and compacted as per project specifications. Minimum top coverage shall be
300 mm. This shall be in accordance with finalized specification document.
Back-Drop Connection- In some instances, there may be a significant level difference between the
incoming pipe and the invert level of the manhole. To accommodate this, and to avoid having to
excavate to full depth for the incoming pipe, a Drop shaft connection may be used.
The incoming pipe is projected through the chamber, to enable rodding and CCTV access, and then
stoppered. A tumbling bay junction will be used to divert the flow downward, through the vertically
set backdrop pipe and then via the knuckle bend to enter the chamber at invert level.
33. TYPICAL BACKDROP CONNECTION DETAIL:
Rocker pipe- if tanking is not provided to concrete surround to pipes, concrete surround shall be in
src20, and tanking shall be turned and lapped 150 dn to pipe surround
The rocker pipe connecting sewers to the manhole shall have sufficient cast-in-situ concrete surround
and an extended concrete base.
34. SWABBING/CLEANLINESS OF PIPELINES:
Before Testing, cleaning and swabbing of the pipeline shall be carried out.
Pipelines and manholes shall at all times be kept free of all silt, mortar, debris, and other obstructions.
When work is not in progress the open ends of the pipeline shall be securely plugged with an approved
watertight plug or stopper firmly fixed to resist unauthorized removal.
The inside of each fitting and pipe length shall be cleared immediately before jointing and shall swab
all fittings and pipe lengths to remove all dirt, sand, or other matter that may clog the pipeline or
contaminate the fluid to be transported in the pipeline.
After jointing, the interior of the pipes shall be freed from any dirt, stones, or other matter that may
have entered them. For this purpose, a rubber disc, brush, or other suitable implements that will not
harm the internal lining of the pipe shall be pulled through the pipe after jointing.
35. TESTING:
Testing a pipeline shall be carried out before any backfilling takes place and shall be repeated after
backfilling is completed, and should be in accordance with the standard specifications of water and air
testing of drain and sewers.
Each pipeline 600 mm or less in diameter shall be tested by air test. If any pipe fails the air test, the
Consultant /Engineer may order a water test (of 5m head/half bar) to be carried out.
Acceptance of the pipeline will then be based on the results of the water test. All pipelines up to and
including 1200 mm shall be tested by air test in accordance with the requirements of BS EN 752.
Pipelines shall be tested in lengths between manholes.
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Each pipeline shall be tested before backfilling and also after backfilling before carrying out road
reinstatement or laying new road surfacing. Where the pipeline is located under a new road alignment,
the pipeline will be tested after the sub-base compaction is complete.
All pipelines shall be subjected to pass infiltration tests as specified herein. All pipes are to be clean
and empty at the time of testing. Tests shall be performed in the presence of the consultant/Engineer.
36. AIR TESTING OF A PIPELINE:
Prior to Air Testing INR will be raised for approval of the installation of piping work.
Air testing of drainage will be carried out prior to closing / backfilling the trench.
Piping may be tested in sections or in total, depending on on-site requirements.
Trained Personnel will conduct the test monitored by a responsible site engineer and safety
department.
37. METHODOLOGY:
Ensure that the pipes and fittings are capable of withstanding air leak tests.
Air testing can be applied to the system in its entirety or in sections. Once the above is checked and
found acceptable, proceed with the test.
Inspect pipeline for possible damage during or subsequent to laying.
Thoroughly check all plugs and equipment. The average drain plug is quite often not airtight and
rubber tubing used in connections must be in good condition and not perished.
Ensure that the ends of the line are adequately strutted against movement with all plugs held firmly in
position.
Pump or blow in the air until a pressure of slightly in excess of 4 inches (100mm) water gauge is
indicated on the manometer connected to the system. Pumping or blowing warms the air so a minute
or two should be allowed for this to cool to the pipe temperature.
If necessary, then reduce the pressure to 4 inches (100mm) water gauge. During a further period of 5
minutes, the air pressure should not fall below 3 inches (75mm) water gauge.
The testing team will conduct a soap test at the joints if an air leak is identified.
If any leaks are detected then they are to be attended to prior to proceeding further.
Repeat the procedure after attending to the leaks (if any).
Once it is confirmed that there is no leak in the system and maintain pressure in the piping for 5
minutes.
INR will be raised for the client/ consultant to witness the Air Test.
After consultant inspection, the system will be vented until normal pressure is attained.
38. PROCEDURES FOR HANDLING AIR TEST FAILURE:
I) Before Backfill
a) Readjust the pipe pressure to the specified test pressure and examine for leakage by pouring a
solution of soft soap and water over the exposed joints if the test fails.
b) Repair leaks and repeat testing where leaks are found at joints.
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c) Where leaks are not found at joints, move the plug, the one that is not used to exert air pressure,
along the pipeline to isolate lengths with leakage. Uncover pipe barrels in the isolated lengths where
leakage in pipe barrels is suspected. Replace leaking pipe lengths and repeat testing.
d) Conduct low-pressure water testing to verify that the air test was not erroneous where the test
length fails the air test but no source of leakage can be identified. Consultant’s consent is required as
per site conditions.
II) After Backfilling
a) Move the plug up from the other end along the sewer pipeline to isolate the lengths that fail the air
test.
b) Exhume the failed length of the pipeline and replace pipe lengths.
c) Repeat the air test.
d) Conduct water testing to check that the air test was not erroneous when failed lengths could not be
isolated using the air test. Consultant’s consent is required as per site conditions.
e) Use CCTV or a suitable recording medium, when required or available, to identify the leakage if the
failed section cannot be isolated by the air test or water test.
39. WATER TESTING OF A PIPELINE:
(Shall be done after consultant’s approval where Air Test failed)
Preparation
Before testing, attention should be paid to the following points:
1. Inspect pipeline for possible damage during or subsequent to laying.
2. Plugs, should be thoroughly checked. Faulty plugs will invalidate test results.
3. Close all openings in the line with watertight seals (Test Stoppers) ensuring against movement. i.e.
all plugs held firmly in position.
4. Ventilating valve should be fixed at the high point of the section.
40. METHODOLOGY:
All the joints of the pipeline shall be able to withstand a pressure of a minimum 5m head of water,
above the crown of pipe at the highest point of the pipeline without leakage. A layer of embedding soil
equal to the diameter of the pipe shall be laid over the pipe to prevent the lifting of pipe while
applying test pressure. However, all the joints shall be left open for the purpose of inspection for
leakage if any. All branches and open ends shall be closed with stoppers, secured with longitudinal
braces/thrust block before testing begins.
Water shall be filled from the lowest point and air allowed to escape through an air vent fixed for the
purpose at the high points of the pipeline section under test. The diameter of the air vent shall be
about one and half times the diameter of the water inlet pipe to allow easy escape of air. No
entrapped air shall remain in the pipeline while testing.
A pressure of 5 m head of water shall be maintained for one hour to allow initial absorption of water.
After that, the test pressure shall be maintained for 15 min and water added shall be measured. If
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water consumption in 15 min does not exceed 0.1 l/m2 of wetted inner pipe surface and if there is no
visible leakage through joints, the pipeline shall be treated as passed.
41. INFILTRATION TESTING A PIPELINE:
GENERAL
This test method defines procedures for hydrostatic infiltration testing of new installations of vitrified
clay pipelines, to demonstrate the structural integrity of the installed line as per ASTM C 1091 – 03a.
This test method is suitable for testing gravity-flow pipelines constructed of vitrified clay pipe or
combinations of clay pipe and other pipe materials.
This test method is applicable to the testing of the pipelines only.
The upper ends of the sewer and service connections shall be closed sufficiently to prevent the entry
of water and pumping of groundwater shall be discontinued until the groundwater surface reaches
its natural level before beginning the infiltration test.
The dewatering system shall be stopped, but not be removed until the infiltration test has been
successfully completed or as otherwise permitted by the Consultant/Engineer.
PROCEDURE
The hydrostatic infiltration test procedure is applicable where the measured water table is 2 ft (610
mm) or greater above the pipe barrel at the lower manhole of the test section. Where the
groundwater elevation is indeterminate, less than 2 ft (610 mm) above the top of the pipe barrel, or
the line is partially below the water table, use a combination of both the air test and infiltration
procedure.
Note 1- the most practical method for testing is Air Test Method and is recommended.
However, where groundwater is present and meets the criteria established in this procedure, the
infiltration test procedure outlined in this practice is recommended.
Note 2- what can be called false infiltration represents condensate on the pipe walls.
The infiltration shall not exceed 6 liters per mm diameter per kilometer per day of the portion of the
sewer being tested, including the length of service connection entering that section.
The total length tested in one section shall not exceed 400 m in length. This length is dependent
upon the type of deflection measuring equipment proposed by the contractor if flexible pipes are
used.
No gravity pipeline will be accepted if the total infiltration exceeds the above-mentioned limit and
joints will not be accepted if, during an internal inspection, any infiltration is visible.
If the test section includes more than one pipe size, calculate the allowable test rate for each size and
add to arrive at the total allowable test rate for the test section.
External drainage pipelines shall be tested for infiltration after backfilling. All inlets to the system
shall be effectively closed, and any residual flow shall be deemed to be infiltration.
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The pipeline shall be accepted as satisfactory if the infiltration, including infiltration into manholes, in
30 minutes does not exceed 0.5 liters per linear meter per meter of the nominal bore. This
relationship in equation format, with water infiltration measured in liters, can be written as follows:
Maximum volume of infiltration over a 30 minute period = 0.5 x L x D Where: L = pipe diameter (m) D
= Length of test section (m)
42. CCTV SURVEY:
CCTV survey shall be carried out on a representative sample of no more than 12% of the length of
constructed pipelines if the Consultant/Engineer’s representative requires.
In case this survey indicates sections of the pipeline fail to meet the specification requirements,
undertake additional CCTV after remedial works will be carried out.
Note: CCTV & Deflection test shall be carried out by a specialized party approved and listed in the
updated list of vendors. The pipeline locations and diameters to go under this test may be selected by
the concerned authority.
SETTING-UP OF EQUIPMENT:
Place visible signage i.e. “System under Pressure”, “Keep Away”, “Danger”, “Caution”.
Warning notices and barricades (if deemed necessary) will be used to identify the system under test.
Clean-up and restoration
After a successful test, remove carefully all temporary plugs.
Remove warning signage and temporary barricades in a safe and orderly manner such that the work
area is restored as is prior to conducting the test.
Clean the work area thoroughly prior to transfer to another test location.
43. HEALTH SAFETY AND ENVIRONMENT
43.A. HSE RISK ASSESSMENT
Please refer to the attached document in Appendix A.
43.B. PERMIT AND LICENSING REQUIREMENTS
The required permit to work shall be obtained prior to commencement of work. This shall be
coordinated with HSE. Site interface permits to be taken from other contractors before placing pipe
at tie-in point to reconfirm IL and coordinates.
43.C. PRE-START SAFETY BRIEFING ARRANGEMENTS
C.1 Protective and Safety Equipment
All workers Involved shall be equipped with adequate PPE as stated below:
Safety Helmet with Company Logo
Safety Boots
High Visibility Vest
Safety Goggles
Hand Gloves
Coveralls
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Proper safety harness
C.2 Information to Personnel
Safety Induction
Job training
– All the personnel involved in this task shall be provided training and only trained personnel shall be
authorized to work around this area.
Toolbox talks
STARRT Card
C.3 Special Safety Requirements:
All necessary personal/protective equipment (PPE), as well as harness, be provided.
Rigging Team, wearing distinctive vests, shall be assigned to help operators maneuver their
equipment.
The equipment operators shall possess the required licenses and certificates.
The required permit to work shall be obtained prior to commencement of work.
The project safety officer is responsible along with the project zone site engineer for ensuring that all
operations are carried out with due regard to the safety of all project personnel & property.
• Working at height to be monitored with due care.
• In case of working at night, please refer to Method Statement for Night Works
• Contractor must provide a safe place of works, with safe access and egress. Provide a safe working
environment that is without risk to health.
44. QUALITY ASSURANCE AND QUALITY CONTROL
44.A. QUALITY ASSURANCE REQUIREMENTS
The contractor shall provide the required documents for the Consultant’s approval prior to initiating
the execution of this activity as per project specification.
The Quality Control requirement shall include related ITP’s and other related documents as
applicable.
44.B. QUALITY ASSURANCE PROCESS
The contractor shall notify the Engineer 24 hours in advance prior to the start of activity and
comments from the site instruction will be complied with the satisfaction of the consultant. The
contractor shall consult the public utility authorities not less than one month before it is proposed to
commence work to ascertain whether any underground installations will be affected by the proposed
work, in which event the contractor shall make all necessary arrangements with the public utility
authorities to safeguard the installation.
44.C. FOLLOW UP AND EVALUATION
Follow-up on quality performance shall be carried out through an in-house monitoring system such
as progress reporting to the planning department, daily, weekly and monthly reports generated by
the planning department to closely monitor site performance.
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All the above shall be conducted in close coordination with the quality department to monitor any
deviations from the Quality Management System requirement and induce corrective actions
whenever required to eliminate non-conformance or quality deviations.
44.D. RECORDS
Checklists (CL)
Inspection Request (INR)
Inspection and Test Record (ITR)
45. ATTACHMENTS
A. Appendices
Appendix A: HSE Risk Assessment for Installation and Testing of Glass Reinforced Pipe (GRP) for Storm
Water Network
Appendix B: Inspection and Test Plan for Installation and Testing of Glass Reinforced Pipe (GRP) For
Storm Water Network
Appendix C: Checklist for Installation & Testing of Glass Reinforced Pipe (GRP) for Storm Water
Network
Appendix D: Checklist for Site Readiness for Installation & Testing of Glass Reinforced Pipe (GRP) for
Storm Water Network
Appendix E: Pressure Test Report for Glass Reinforced Pipe (GRP) for Storm Water Network
Appendix F: Sewer Record Sheet
Appendix G: Permanent Material Delivered Approval Form
Appendix H: Location, drawing for storm water network
Appendix I: BOQ for stormwater network
Appendix J: Installation guide for underground pipe
Appendix K: Manufacturer’s method statement for installation of storm water network (GRP Pipe)
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METHOD STATEMENT FOR
BOLT TIGHTENING
SR. EFFECTIVE REV. MSS MANAGER MSS PROJECT CLIENT
CLIENT QA/QC
NO. DATE NO. QA/QC MANAGER SUPERVISOR
BOLT TIGHTENING
1. PURPOSE
The method statement for bolt tightening describes the methodology and testing for torquing bolts in
structural steel used in mechanical equipment provided to commercial buildings, plants, refineries,
and their equipment structures.
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2. SCOPE OF WORK
The scope of work includes bolt tightening requirements of all mechanical equipment structural joints
and sections showing the bolt size to be used, field inspection, and implementing safety precautions
during work execution to prevent accidents.
3. REFERENCES
Work shall be performed according to project applicable standards and project specifications:
High Strength Bolt Tightening Inspection and Testing (ASTM A325/A490 Bolts)
Pre-Installation Procedure Verification Testing Turn-of-Nut Method (ASTM A325/ASTM A490 bolts)
Pre-Installation Procedure Verification Testing of Calibration Wrench (ASTM A325/ASTM A490 bolts)
Structural alignment inspection during erection
Correcting structural alignment errors
Pipe Racks, Steel Supports, and Miscellaneous Steel Structures
4. MANPOWER
Structural Steel Foreman/Mechanical Foreman
Structural/Mechanical Skilled Workers
Manlift Operator
Flagman
QC Inspector
5. TOOLS AND EQUIPMENT
Torque Calibrator
Calibrated Torque Wrench
Hammer Wrench
Impact Wrench
Spud Wrench
Manlift
6. PROCEDURE – METHOD STATEMENT FOR BOLT TIGHTENING
5.1 PREPARATION OF SITE AND MATERIALS
Unless the contract documents specify otherwise, determine which type of bolt materials will be
used.
High-strength A325 or A490 bolts are required for all primary structural frames and some secondary
framing.
5.2 REQUISITION OF A SPECIFIC NUMBER OF BOLTS
Steel members to be joined must be free from oil, grease, or any loose adherent materials.
Any circumstances discovered by the contractor that have an impact on the progress, performance,
or completion of work activities, such as discrepancies between drawings and delivered steel
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members to be jointed, incorrectly fabricated steel members, or incomplete or unacceptable
material, must be reported in writing.
Before tightening the bolts, the contractor must double-check the connection points’ location,
position, elevation, and quality.
To prevent injury while starting the work, the contractor must set up scaffolding, access, ladder,
wood boards, or floor plates for the structural/mechanical workers who will be doing the task.
5.3 STABILITY OF THE STRUCTURE
The contractor is responsible for the availability and installation of any temporary bracing or guy
cables needed to counteract the induced loads at all times. This responsibility also includes any
temporary bracing required to keep partially constructed structural assemblies safe and stable.
Before final bolting connections are made, the structure must be plumbed, leveled, and braced.
7. CONNECTIONS WITH BOLTS
The materials, method of installation, tension controls, types of wrenches to be used, and inspection
processes for structural joints formed using high-strength bolt assemblies must all comply with
the AISC Specification for Structural Joints Using ASTM A325 or A490 Bolts.
When using a direct tension indicator washer, make sure you follow the manufacturer’s instructions.
All bolts must match the shop drawing, erection drawings, or other contract documents accurately.
8. BOLT TIGHTENING
After aligning the holes in the joint, adequate bolts should be installed and tightened to a Snug–
Tight condition to guarantee that all portions of the joint are in complete contact with each other.
As defined, “Snug-Tight” refers to a person’s effort with a spud wrench or the tightness achieved with
a few impacts of an impact wrench.
7.1 USING THE SPUD WRENCH METHOD FOR MANUAL OPERATION
In this instance, a man using a standard spud wrench would be able to tighten the bolt to a snug fit.
To avoid tension, no wrench extension or long wrenches should be used; a standard spud wrench is
normally 12 inches (300mm) long.
7.2 USING IMPACT WRENCH METHOD
A few strikes with an impact wrench should be enough to tighten the nuts and bolts up snugly. This
operation should not take more than 30 seconds if the impact wrench is powerful enough to apply to
bolts that have already been tightened to full contact with the steel connection plates.
Once the snug-tight position is attained, a straight line on the bolt head should be marked with a
metal marker or a pentel pen before going to the nut location. This will show the nut’s starting
position before it is tightened to its final position.
The likelihood of a bolt loosening in a critical-slip connection where the joint is subjected to vibratory
or fatigue loads is very high. In this scenario, an additional jamb-nut may be required after the bolts
have been fully tensioned.
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To prevent the nut from turning, the threads can be spiked or marred, or the nut can be tack-weld to
the base metal.
7.3 DIRECT TENSION INDICATOR
Direct Tension Indicator tightening requires the use of a device that allows accurate measurement of
bolt tension, such as a load indicator washer.
9. OPERATIONS
All bolts in the joints must be further tightened using either the turn-off-nut or calibrated wrench
method after the initial tightening operation.
8. 1 TURN-OF-NUT-METHOD
Once the bolt is snugly tight, the amount of rotation required should be applied to further tighten it.
Refer to the table below for reference.
Disposition From
Table Snug Tight
Condition
One face normal to bolt axis Both faces sloped not more
Bolt length Bottom face
and other sloped not more than 1:20 from normal to the
(underside head to normal to the bolt
than 1:20 (beveled washer not bolt axis (beveled washer not
the end of the bolt) axis
used) used)
Up to and diameter
but not exceeding 4 1/3 turn 1/2 turn 2/3 turn
diameters
Over 4 diameters but
not exceeding 8 1/2 turn 2/3 turn 5/6 turn
diameters
Over 8 diameters but
2/3 turn 5/6 turn 1 turn
not exceeding 12
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diameters
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BOLT TIGHTENING USING THE TURN-OF-NUT METHOD
8.2 CALIBRATED WRENCH METHOD
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Following the initial tightening required, a calibrated torque wrench must be used to tighten bolts to
a tension that is at least 5% higher than the minimum bolt tension as per ASTM A325. See the table
below for reference. For each bolt diameter, length, and grade being fitted, the wrench must be
calibrated at least once a year on a working day. Tightening in a device capable of indicating actual
bolt tension is required for calibration. For each diameter of bolts being installed, three typical bolts
shall be tightened.
Nominal Bolt Size, inches A-325 Bolts A-490 Bolts
KIPS KN KIPS KN
1/2 12 53 15 67
5/8 19 85 24 107
3/4 28 125 35 156
7/8 39 174 49 218
1 51 227 64 285
1 1/8 56 249 80 356
1 1/4 71 316 102 454
1 3/8 85 378 121 538
1 1/2 103 458 148 659
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BOLT TENSION USING CALIBRATED WRENCH METHOD – Table 2
BOLT TIGHTENING USING THE CALIBRATED WRENCH METHOD
8.3 DIRECT TENSION INDICATOR METHOD
A standard impact wrench is used to tighten the bolt with the load indicator washer inserted.
Compressed air is the most common source of power. A sufficient amount of pressure must be
applied to the tool, with a minimum of 100 psi for bolts with a diameter of 7/8″ or less. Pressure
must be increased for larger bolts. Hose lines should be large enough to accommodate the number
and size of wrenches that will be utilized.
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Load Indicator Gaps to Give Required Minimum Bolt Tension
Load Indicator Fitting A325 A490
0.025 0.015
Under Bolt Head Black Finish Bolts
in. in.
0.015 0.010
Under Nut with Hardened Flat Washer Black Finish
in. in.
With the gaps shown above, required minimum bolt tensions will be induced as given
in Table 2
DIRECT TENSION INDICATOR METHOD – Table 3
10.QUALITY CONTROL
Prior to beginning the work, inspect the physical appearance and material specifications for bolting.
For bolt specification requirements, including diameters and manufacturer’s recommendations, make
sure to refer to the IFC drawings. Always follow the standard compliance criteria.
Check, verify, and continuously monitor bolting work activities on the job site and in the laydown yard
where assembly and bolt tightening are taking place.
For final acceptance, a Request for Inspection is to be submitted.
11.SAFETY
Ascertain that all workers are wearing the appropriate personal protective equipment (PPE).
To prevent injury to all personnel exposed by the operations, place warning devices such as warning
tapes, signboards, and barriers around the work area.
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Tools (both hand and machine-operated tools) and safety harnesses must be monitored and coded
according to safety monthly monitoring guidelines to ensure that they are accepted and comply with
daily site activities.
11.Attachments –
Method Statement for Bolt Tightening
Job Safety Analysis
Inspection Request Form
METHOD STATEMENT FOR
FM 200 FIRE
SUPPRESSION SYSTEM
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SR. EFFECTIVE REV. MSS MANAGER MSS PROJECT CLIENT
CLIENT QA/QC
NO. DATE NO. QA/QC MANAGER SUPERVISOR
FM 200 FIRE SUPPRESSION SYSTEM
1. PURPOSE
This Method Statement of FM 200 Fire Suppression is applicable to its installation and testing system for
the project as specified in specifications and manufacturer’s instructions.
2. SCOPE
Clean agent system methodology covers the equipment setting procedures and installation technique as
well as the sequence of operation for the Fire Suppression System.
This includes brief descriptions but is not limited to the following:
FM 200 Clean agent extinguishing agent also known by its ASHRAE designation as HFC-227ea
(Heptafluoropropane)
Agent storage container and accessories
Discharge nozzles
Extinguishing panel
Automatic fire detectors
Automatic and manual agent release units
Abort station (optional)
Audible and visual alarms
Other related hardware
Installation of FM 200 fire suppression system shall be as per NFPA 2001 & NFPA72 codes.
The specialist sub-contractor “xxxxxx” will be utilized to undertake the engineering, supply, installation,
testing, and commissioning for the FM200 system.
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Note: After the system installation has been completed, the entire system shall be checked, inspected,
and functionally tested by a qualified and approved 3rd Party Specialist, as per the manufacturer’s
recommended procedures and NFPA 2001 guidelines.
3. SYSTEM DESCRIPTION
What is FM 220?
FM-200 is a clean colorless and environmentally friendly fire suppression agent that is electrically non-
conductive and safe for humans. It extinguishes flames through heat absorption, leaving no residue, thus
minimizing downtime after a fire and making the FM 200 suppression system accepted and respected
worldwide.
This system consists of the following component and their associated accessories:
Basic pipes and pipe fittings
Control panel
Storage cylinder
Discharge valve
Discharge nozzle
Pressure switch
Smoke detector
Graphic annunciators
Battery backup power system
Alarm horn
Abort switch
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FM 200 FIRE SUPPRESSION SYSTEM
4. DEFINITION
Client – xxxx
Project Management-Construction Management (PM-CM) – xxxx
Construction Supervision Consultant (CSC) – xxxx
Main Contractor – xxxx
Supplier/Vendor – Seller of material as defined in the project specification
Must – Signifies a legal or statutory requirement
Shall – Signifies a requirement made mandatory by this specification
May – Signifies a feature, which is discretionary in the context in which it is applied.
Will – Signifies feature which the supplier may assume to be already present
5. REFERENCES
NFPA 2001
Project Specifications
Manufacturer Literature
Approved Shop Drawings
Approved Material submittal
Pipes & Fittings for FM 200 System
Basic Requirements (Pipes, tubes, fittings)
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6. ABBREVIATIONS
NFPA-National Fire Protection Agency
HSE-Health, Safety, and Environment
MST-Method Statement
RSK-Risk Assessment
ITP-Inspection & Test Plan
QCP-Quality Control Procedure
INR-Inspection Request
PPE Personnel Protective Equipment
STARRT-Safety Task Analysis Risk Reduction Talk
MSDS-Material Safety Data Sheet
PQP-Project Quality Plan
7. RESPONSIBILITIES
7.1.General
Project Manager (MEP) will be responsible to manage, execute, complete and handover the
construction activities within approved budgets and resources in compliance with Project
Requirements as specified in Project Specifications. He will be overall in charge of
implementing Method Statement in accordance with QA/QC and HSE requirements.
Construction Manager will be responsible for managing construction activities and will lead and
communicate site supervision, subcontractors and Vendors to assist them in working to the Project
Schedule and HSE requirements at site.
HSE Manager will be responsible for planning, coordinating, and implementing issues and directives
within the organization. He ensures safe environmental working conditions for all employees.
QA/QC Manager will be responsible for supporting the project team in implementing and maintaining
Quality Management System for the project through POP, ITP, MST, and Procedures in compliance
with Project specifications, Codes, and Standards.
HSE Officer will ensure enforcement of safety procedures in accordance with the approved HSE Plan.
Will be closely monitoring the site engineer’s strict implementation of the method statement of FM
200 and risk assessment, the use of proper tools and equipment to maintain safety, certifications of
equipment and their adherence to safety regulations, reporting of any unsafe work or stopping work
that does not comply with HSE procedures.
Site Engineer will be responsible for carrying out all construction-related activities with compliance to
HSE and QA/QC requirements as per contract specifications, drawings/ documents, codes, and
standards.
QA/QC Engineer will be responsible for conducting inspections as per PQP.
Supervisor/Foreman will be responsible for coordinating all works and workers related to the job.
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Electrician/other tradesmen will be responsible for assisting his superiors during all construction
work-related activities following HSE and QA/QC requirements.
Store In-charge receives and inspects all incoming materials and reconciles with documents;
processes and distributes documentation; reports, documents and tracks damages and discrepancies.
Security guards will be clearly visible, vigilant, respond quickly and correctly during the crisis, observe
and report, check and monitor, maintain order among workers, and offer safety warnings and tips.
8. LIST OF SUBCONTRACTORS
Subcontractors for MEP: xxxx or Specialized sub-contractor
9. HANDLING, STORAGE AND TRANSPORTATION
All materials shall be handled/transported/stored in an optimal way that will not cause damage to them.
Pipe shipping, storage, and handling shall comply with the manufacturer’s recommendations.
The material will be delivered at the site in undamaged condition, in the Manufacturer’s packaging, with
identifying labels intact and legible.
Each shipment must be blocked and securely fastened to avoid damages during transportation.
Unloading at the site must be controlled by site management following the manufacturer’s instructions.
Rubber gaskets should be kept clean and away from oil, grease, excessive heat, and the direct rays of the
sun.
Pipes are to be checked on unloading. Damaged and defective pipes shall not be used at the site. The pipe
shall be re-inspected just prior to installation. Possible damages are reported on the delivery note.
Pipes or fittings will not be dropped or dragged.
Ensure that the material is stored in the shaded area to protect it from exposure to direct sunlight.
Leave sufficient space between individual pipes.
The storage area shall be cleaned and is at an appropriate height from the ground level. Separate areas in
the storage zone must be marked for different materials.
Whenever heavy or bulky material is to be moved, the material handling needs will be evaluated in terms
of weight, size, distance, and path of movement.
The pipes and fittings while unloading shall be slowly lowered and not dropped to the ground.
All piping shall be shipped to the job site with suitable end caps.
End caps should not be removed, but only just before the installation.
Store pipes and fittings in covered areas for protection.
Pipes shall be stacked on a flat surface with adequate wooden supports kept at equal distances apart.
9.A GENERAL:
Before commencing the installation of the pipes and fittings the following shall be carried out:
On receipt of the pipes and fittings storage shall be arranged at the site as per the manufacturer’s
recommendations so as to prevent any physical damage to the material.
Check that approved materials are available for installation.
All materials must be offered for inspection by the consultant prior to any fabrication/installation work.
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Check issued for approved construction drawings are used for installation.
Check that the work area is clean and safe for work.
Ensure installation work is undertaken only by trained and experienced personnel.
Check painting work is carried out during different stages of installation, one coat of primer and one
coat red paint before installation and one coat of paint after installation.
Ensure threading, grooving, and fabrication of pipework are as per approved drawings and
specifications.
10. MATERIAL RECEIVING
Deliver materials in manufacturer’s original packaging labeled to show name, brand, type, and grade.
Deliver materials in a timely manner and as per schedule sequence and priority areas.
Conduct material inspection request as per approved procedure after delivery and prior to material site
usage.
Check for UL and/or FM listing in the items delivered as called for in the project specifications and
applicable codes.
11. STORAGE AND PROTECTION
Store materials in protected dry locations off-ground in accordance with the manufacturer’s instructions.
Do not open packaging nor remove labels until the time for installation.
Storing of pipe and fittings in the desired location provided by the client.
12. MATERIAL INSPECTION
For materials to be inspected after receiving at the site, the following points are to be followed:
Each material item shall be allotted a distinct and separate reference number and mentioned on the
material requisition. Make sure that material is approved/examined by the consultant and QC inspector
and associated documents/test certificates are approved.
The Store In-charge shall ensure that all approved supplies be delivered to the site as per the approved
material submittal; with the manufacturer’s seals, labels, or other proof of origin intact. These labels and
seals shall not be removed until the material is required for use and shall be retained for inspection by the
consultant and QC inspector.
Store In-charge shall initiate material inspection for all incoming material to QC inspector and the material
shall be inspected against reference documents and as per approved material submittal. Moreover, the
physical condition of the material shall be checked. Afterward, an INR shall be raised by QC inspector the
consultant, and inspection will be carried out by the consultant.
Materials, which do not conform to the given specification/material submittal, shall be rejected. Any
discrepancy or damages will be notified and reported for further action.
For any materials inspection (especially pipes, fittings, other accessories), the items shall be segregated as
per their type/sizes and placed items separately in racks or on different pallets.
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Each rack/pallet shall have an identification posted on a laminated paper with the description of the items
clearly written on it.
There shall be appropriate spaces between the pallets so that the engineer/inspector can freely go
around them and inspect the materials thoroughly. Staking the materials all over each other & in one
corner is strictly not allowed.
13. RESOURCES
13.A. TOOLS AND EQUIPMENT
The job will be carried out by manual means. The following are the types of tools identified for works:
Pipe wrench
Pipe fitter toolbox with complete hand tools
Spirit level
Marking pen
Masking tape
Measuring tape
Cleaning brush
Drilling machine
Threading machine
Mobile scaffold
AC Arc welding machine
PPE (hand gloves, face masks, safety goggles)
Safety Harness (for high-level work)
Trouble light
Note:
All testing equipment and measuring tools to be used shall have a valid calibration certificate prior to
usage. All lifting equipment and machines shall be 3rd party verified with valid certificates.
13.B. MATERIALS
Material includes but is not limited to the following:
Pipes-Seamless Carbon Steel Pipe, Schedule-40, ASTM A-53
FM 200 System Materials
Fittings/Joints-Class 200/300 Malleable or Ductile Iron fittings up to 80mm and Class 1000 flanged
joints for 100mm and larger
Agent FM-200 Clean Agent (Also known by its ASH RAE designation as HFC-227ea)
Agent Storage Container- FM 200 / HFC 227ea container, discharge assembly & accessories
Actuation & Monitoring Device-Agent Release Module, Gas Cartridge Actuator & Low-Pressure
Switch
Discharge Nozzle-Engineered Nozzle
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Manual Actuator- Manual Operated Actuator
Fire Detectors
Control Panel
Abort Station
Photoelectric Smoke Detectors
Conventional SHP Extinguishing Panel
Abort Switch
Notification Device -Alarm Bell & Horn/Strobe as specified or approved alternative
a. The material shall be used after being approved through Material Submittals.
b. All material to be used shall conform to the Project Specification and Authorities regulations (where
required).
13.C. LIST OF MANPOWER
Construction Manager
Site Engineer
QA/QC Engineer
HSE Officer
Supervisor
Foreman
Pipefitters/Installers
Surveyor
Helpers
Trailer Driver
Mobile Crane / Crane Operator
Forklift Operator
Riggers
Welder
Electrical Technician
Helper
14. MOBILIZATION
14.A. PREPARATION AND PLANNING
The contractor shall ensure that all gate passes, permits, tools, materials for safety precautions,
manpower, and equipment are available before commencement of work.
The Site Team shall make sure that access roads are always clear from any obstruction and the site is
always accessible.
14.B. SITE CLEARANCE
Before commencing the work, the area shall be cleared of all debris, materials, or other obstructions.
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15. WORK METHODOLOGY
The installation of FM-200 system piping will be according to the following:
Methodology
Please See the Attached Manufacturer’s Method Statement at “APPENDIX F” for the Installation of FM
200 Fire Suppression System extracted from approved Material Submittals.
Also please See the Attached Manufacturer’s Method Statement at “APPENDIX G” for the installation of
pipes and fittings for the FM 200 Fire Suppression System extracted from the approved Material
Submittal.
15.A. PRELIMINARY WORKS
Verify the sizes of pipe sleeves and location as shown on the approved shop drawing and are clear of
any obstructions.
Whenever pipes pass through slabs, wall partitions, etc., the size of the sleeve will abide by the pipe
sleeve.
Clean pipe surface and apply a coat of appropriate primer prior to installation.
15.B. SYSTEM INSTALLATION
Check that the material size and schedule are correct and approved as per specification and/or
approved alternative.
Ensure that the pipes and fittings conform to the requirements as outlined in NFPA 2001 in strict
accordance with systems-approved plans.
All pipe thread connections must be free of scale and burrs before installation.
Check to ensure that all grooved coupling gaskets are lubricated per the manufacturer’s specifications.
Pipe thread sealants as approved shall be applied to the threads to ensure a water-tight seal.
Ensure that the piping system should be securely supported with due allowance against agent thrust
forces, thermal expansion, and contraction.
Pipe hangers shall be spaced at intervals not exceeding 4.5 meters.
Rigid bracing shall be installed at each directional change, fitting, tee, and nozzle.
Check to ensure that the nozzle identification number is verified before Installation and each nozzle
should be within 25mm to 300mm of their intended locations on systems plans.
Check to ensure that piping should be blown clear to remove chips, mill scale, metal shaving before the
nozzle should be installed.
Make certain that each container has been installed in the correct mounting position and shall be
located in a clean, dry, and relatively vibration-free area.
Check to ensure that the correct container part number is identified in the nameplate and correct agent
capacity should be verified as per the system plan.
Verify that the container pressure gauge is within the fill pressure range of 60 psi at 70 °F.
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Make sure that the container brackets must be mounted securely to a solid Bearing Surface that will
support the container load.
All conduits & hardware, initiating & signaling devices, and other related electrical connections shall be
done as mentioned in the specification with the approved materials and manufacturer in accordance
with the minimum requirements in NFPA 72.
Check to ensure that Gas Cartridge Actuator and Agent Release Module should be the last items to be
installed before the system is placed in operation.
Verify that all auxiliary functions such as door closures, damper closures, air handling shutdown, etc. are
connected as specified.
On completion of the works, all elements of the installation shall be checked to ensure the installation is
in compliance with the specification and manufacturer instructions.
All pipes and equipment installation works shall be monitored on an ongoing basis to ensure compliance
with the quality requirements of the project.
The system shall be identified in compliance with the specifications, identifying all equipment, flow
direction, and services.
15.C. INSTALLATION PROCEDURE FOR THREADED JOINTS
Pipes size DN 50 and smaller will have threaded joints as per specification and approved materials.
Using threading machine, thread pipe with tapered threads according to Specification of threaded
fittings approved.
Cut threads full and clean using sharp dye.
Ream threaded pipe ends to remove burrs.
Note the internal length of threads in fittings or valve ends, and the proximity Internal seat or wall, to
determine how far pipe should be threaded into the joint.
Provide as sealing thread-‘JUTE’ fiber to establish satisfactory jointing technique and leak-free pipework.
Apply appropriate Teflon tape or thread compound to external pipe threads.
Align threads at point of assembly.
Tighten joint with the wrench. Apply wrench to valve end into which pipe is being threaded.
Do not use pipes or fittings with damaged or corroded threads.
Do not use pipe sections that have cracked or open weld.
15.D. INSTALLATION PROCEDURE FOR GROOVED FITTINGS
The installation is based on pipe grooved in accordance with a standard cut groove or roll grooved for
flexible coupling.
Inspect exterior grooved and ends of the pipe to verify all debris, dirt, chips, paint, and any other foreign
material such as grease are removed. Pipe and sealing surfaces must be free from projections,
indentations, or other markings.
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Verify that the coupling and gaskets grades are correct for the application intended. Please refer to the
‘Gaskets’ section of the Manufacturer catalog for additional information. The edges and outer surfaces
of the gaskets should be covered with a fine layer of lubrication.
The edges and outer surfaces of the gaskets should be covered with a fine layer of petroleum-free
silicone lubricant or equivalent – refer to the Manufacturer’s instruction.
Petroleum lubricant should not be used on Grade “E” “EPDM” gaskets to prevent deterioration of the
gaskets materials. Tri-seal gaskets are recommended for freezer applications.
Install the gaskets by placing the gaskets over the pipe, which is to be fastened by the flexible coupling,
and ensure that the lip of the gasket does not extend beyond the end of the pipe.
Bring both pipe ends together, ensure proper alignment and slide the gasket into position, properly
centering it between the grooved portions of each pipe.
The gasket should not protrude into the grooves on either pipe segment or extend between the pipe
ends.
With one nut and bolt removed, “swing around”. Verify that the housings are over the gasket and that
the housing keys are fully engaged into the grooves.
Insert the other bolt into the coupling and rotate the nuts until finger tight.
Verify that the bolt heads are fully recessed in the housing.
Alternate between bolts when tightening nuts until properly torqued to bring housing in contact with
the bolt pads.
Uneven tightening can cause the gasket to pinch or bind. For proper bolt torque – please refer to the
Manufacturer’s instructions.
Remove tools, debris, unused materials, and clean the area after the installation has finished.
15.E. INSPECTION & PIPE INSTALLATION TESTS
After the installation has been completed, the entire system shall be checked, inspected, and
functionally tested by qualified and approved 3rd Party Specialists as per the manufacturer’s
recommended procedures and NFPA 2001.
The test described hereunder does not include the Room Integrity Test which will be done by the
Specialist, but rather, a systems test for QA/QC purposes as required by NFPA and as a preparation for
further more extensive tests.
Safety will be a major factor during pressure testing to ensure a safe working environment for all on-the-
site personnel and to safeguard plant and equipment.
Prior to commencing testing, a toolbox – the talk will be given to all personnel identifying the potential
dangers of pressure testing and making everyone aware that testing is ongoing in the area. This method
statement will be used as supporting text for the toolbox talk.
Test limits will be indicated on the drawing. The test may comprise a complete system or a part of piping
within a system. Test limits shall be at flanged or similar mechanical joints.
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All in-line instruments (pressure gauges, thermometers, etc.) shall be removed during testing.
Temporary spades/blinds will be installed where necessary at the test limit points.
All test equipment (compressors, manifolds, gauges, etc.) will be inspected prior to use to make sure
they comply with the site safety requirements. All gauges shall have a valid calibration certificate
available for inspection. Generally, two gauges will be provided per test, one at the high point possible
and one at the lowest point possible.
Before testing commences the client will be advised twenty-four hours in advance, by a “Request for
Inspection” of the intention to proceed with such testing and the intended location of any such test.
Testing will be coordinated through the main contractor so as not to affect or to interfere construction
schedules of the main contractor or other related specialist sub-contractors on site.
Prior to introducing air to the system, all piping shall be checked thoroughly for tightness. A preliminary
blowdown of the system should be done to remove small particles in the piping before the test.
Testing shall be in accordance with the project specifications and guidelines in NFPA 2001.
The piping shall be pneumatically tested in a closed circuit for a period of 4 hours at 50 psi. At the end of
10 minutes, the pressure drop shall not exceed 20 percent of the test pressure soap & water solution
may be applied to joints for faster leak detection.
Equipment shall be omitted from tests and bypass arrangements shall be tested. Temporary
spades/blinds will be installed where necessary at the test limit points.
Prior to testing, a demarcation area will be taped off and warning signs placed prominently, stating
clearly that hydrostatic testing is in progress.
These demarcation areas will be no entry areas for all personnel with the exception of testing inspectors
and test personnel. The demarcation area limits may vary greatly in relation to hydrostatic testing is in
progress.
Pressurizing of the system will proceed on an incremental basis.
Test pressure results will be recorded on a pressure test certificate. safety.
Test pressure results will be assessed on a test-by-test basis to be agreed on-site and shall be carried
without environmental contamination.
When all aspects of testing are completed the demarcation area will be removed and all barriers and
signs stored in a safe/tidy manner.
Inspections and tests shall be witnessed, recorded and Inspection Test Plan (I.T.P) will be signed by the
sub-contractor Quality Engineer, Contractor QC & Employer’s Representative as applicable on each
form.
15.F. CLEANING, PAINTING, AND IDENTIFICATION
All piping systems will be cleaned and duly painted with 2 layers of primer and one coat of semi-gloss
acrylic-enamel red paints prior to installation of the piping system.
After Successful completion of the pressure test, all piping systems were duly painted with 1 final coat.
Do not paint nameplates, labels, placards, tags, stainless steel or plated items, valve stems, motor shafts,
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levers, handles, trim strips, etc. Exposed and visible piping, equipment devices and apparatus in FM 200
systems shall be ANSI Standard color.
The “Identification” Stencil 40 mm high white enamel block type characters on all items of equipment
for identification purposes. Also, stencil a complete system of pipe identification adjacent to each valve
and branch Note: For the identification/labeling, a separate Method Statement will be submitted once
the Material Transmittal has been finalized.
15.G. ADDITIONAL INFORMATIONS FOR THE INSTALLATION AND TESTING OF CLEAN AGENT SYSTEMS AS
PER NFPA 2001
Location of Storage Cylinder-Clean agent storage containers shall not be stored within the protected
enclosure. They shall be easily accessible from the main entrance of the protected enclosure.
Mechanical Actuation-A manual mechanical means of discharging the required agent shall be provided
on the storage container.
Automatic Operation-Clean agent systems shall be operated automatically by an authority/government-
approved automatic detection system.
Control Panel-this this shall be located external to the protected enclosure and located near the main
entrance to the protected enclosure. The control panel shall be connected to the building’s main fire
alarm panel and shall provide alarm, gas discharged and fault indications on the Main Panel.
Gas Discharge delay timer to allow occupants escape – gas discharge shall only occur after a
predetermined time delay to be approved by the authority. The time delay shall be interrupted by the
operation of the Abort Switch and shall re-commence on the release of the Abort Switch. The minimum
delay shall be 20 seconds.
Manual Release-At least one manual release push button shall be provided external to the protected
enclosure and mounted within 1.5 m of the main entrance. Subject to the size and configuration of the
protected enclosure, more than one manual release push button may be required. Operation of the
manual push-button shall cause the instant release of the clean agent.
Abort Switch-An abort switch that interrupts the countdown delay timer shall be provided within the
protected enclosure and mounted within 1.5m of the main entrance. Subject to the size and
configuration of the protected enclosure, more than one abort switch may be required. Continuous
operation of the Abort Switch shall be required to interrupt the countdown timer. Release of the Abort
Switch shall reset the countdown timer to gas discharge.
Gas Discharge Signage-illuminated signs shall be external to the protected enclosure and mounted
above all entrances so as to be visible to any person entering. The lettering shall be a minimum of 50mm
high. It shall be visible at all times of the day.
The illumination shall be activated by a pressure switch fitted to the discharge piping. “EVACUATE NOW-
GAS DISCHARGE” illuminated signs shall be provided above the exits of the protected enclosure. The
lettering shall be a minimum of 50mm high. It shall be visible at all times of the day. Illumination shall be
activated by on commencement of the discharge time delay.
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Enclosure Considerations-All enclosures protected by clean agent systems that are required by code to
be provided with an extinguisher system, in the absence of sprinkler protection, must be constructed
from 2-hour fire-resistant elements. Subject to the location of the enclosure, its integrity (to be verified
through testing ), and the type and nature of the clean agent used, a ventilation system to purge the gas
after discharge may be required by the authority.
Due consideration shall be given to this aspect of the system. All enclosures protected by clean agents
systems must be subjected to an Enclosure Integrity Test. The test shall verify the ability of the
protected enclosure to maintain the minimum design concentration for 10 minutes. The enclosure test
must be witnessed by the authorized representative. This is a pre-condition for the issue of the
building’s fire safety certificate.
16. HEALTH SAFETY AND ENVIRONMENT
16.A. HSE RISK ASSESSMENT
Please refer to the attached document in Appendix A.
16.B. PERMIT AND LICENSING REQUIREMENTS
The required permit to work shall be obtained prior to commencement of work. This shall be
coordinated with HSE. Site interface permits to be taken from other contractors before placing pipe at
tie-in point to reconfirm IL and coordinates.
16.C. PRE–START SAFETY BRIEFING ARRANGEMENTS
16.C.a. PROTECTIVE AND SAFETY EQUIPMENT
All workers Involved shall be equipped with adequate PPE as stated below:
Safety Boots
Safety Helmet with Company Logo
High Visibility Vest
Safety Goggles
Hand Gloves
Coveralls Proper safety harness
16.C.b. INFORMATION TO PERSONNEL
Safety Induction
Job training
All the personnel involved in this task shall be provided training and only trained personnel shall be
authorized to work around this area.
Toolbox talks
STARRT Card
16.C.c. SPECIAL SAFETY REQUIREMENTS
All necessary personal/protective equipment (PPE), as well as harness, be provided.
Rigging Team, wearing distinctive vests, shall be assigned to help operators maneuver their
equipment.
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The equipment operators shall possess the required licenses and certificates.
The required permit to work shall be obtained prior to commencement of work.
The project safety officer is responsible along with the project zone site engineer for ensuring that all
operations are carried out with due regard to the safety of all project personnel & property.
Working at height to be monitored with due care.
In case of working at night, please refer to Method Statement for Night Works.
The contractor must provide a safe place of works, with safe access and egress.
Provide a safe working environment that is without risk to health
16.C.d. HEALTH AND WELFARE ARRANGEMENTS FOR PERSONNEL INVOLVED IN THE ACTIVITIES
Make the workplace safe.
Prevent risks to health.
Ensure that plant and machinery is safe to use ensure safe working practices are set up and
followed.
Make sure that all materials are handled, stored, and used safely.
Provide adequate first aid facilities.
Be informed about any potential hazards from the worksite – chemicals and other substances used by
the firm -and give information, instructions, training, and supervision as needed.
Set up emergency plans
Make sure that ventilation, temperature, lighting, toilet, washing, and rest facilities all meet health,
safety, and welfare requirements
Check that the right work equipment is provided and is properly used and regularly maintained.
Prevent or control exposure to substances that may damage your health.
Take precautions against the risks caused by flammable or explosive hazards, electrical equipment,
noise, and radiation
Avoid potentially dangerous work involving manual handling (and if it can’t be avoided, take
precautions to reduce the risk of injury).
Provide health supervision as needed.
Provide protective clothing or equipment free of charge (if risks can’t be removed or adequately
controlled by any other means)
Ensure that the right warning signs are provided and looked after report certain accidents, injuries,
diseases, and dangerous occurrences to either the health and safety guidelines or the local authority,
depending on the type of business officer in charge.
16.C.e. REQUIREMENTS TO PROTECT THE ENVIRONMENT
All unused or excess including wastes during and after any work shall be disposed of properly using
designated garbage bins and to be disposed of outside the project at locations approved by the local
authorities.
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17.QUALITY ASSURANCE AND QUALITY CONTROL
17.1 QUALITY ASSURANCE REQUIREMENTS
The contractor shall provide the required documents for the consultant’s approval prior to initiating the
execution of this activity as per project specification.
The Quality Control requirement shall include related ITP’s and other related documents as applicable.
17.2 QUALITY ASSURANCE PROCESS
The contractor shall notify the engineer 24 hours in advance prior to the start of the activity and
comments from the Site Instruction will be complied with the satisfaction of the consultant.
The contractor shall consult the public utility authorities not less than one month before it is proposed
to commence work to ascertain whether any underground installations will be affected by the proposed
work, in which event the contractor shall make all necessary arrangements with the public utility
authorities to safeguard the installation.
17.3 FOLLOW UP AND EVALUATION
Follow-up on quality performance shall be carried out through an in-house monitoring system such as
progress reporting to the planning department, daily, weekly, and monthly reports generated by the
planning department to closely monitor site performance.
All the above shall be conducted in close coordination with the quality department to monitor any
deviations from the Quality Management System requirement and induce corrective actions whenever
required to eliminate non-conformance or quality deviations.
All remedial actions to be taken, if any, shall take into account the official schedule which is to be used
as a guideline for performance and most importantly under the close supervision of the quality control
department.
17.4 RECORDS
Checklists (CL)
Inspection Request (INR)
Inspection and Test Record (ITR)
18. ATTACHMENTS
APPENDIX A: HSE Risk Assessment for Installation & Testing of FM 200
APPENDIX B: Inspection and Test Plan for Installation & Testing of FM 200
APPENDIX C: Checklist for Installation & Testing of FM 200
APPENDIX D: Location Drawings for the Installation of FM 200 Fire Suppression System
APPENDIX E: Bill of Quantities for FM 200 Pipes and Fittings
APPENDIX F: Manufacturer’s Method Statement of FM 200 Fire Suppression System Installation
APPENDIX G: Manufacturer’s Method Statement for the Installation of Pipes and Fittings for FM 200 Fire
Suppression System
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METHOD STATEMENT FOR
MICC CABLES
SR. EFFECTIVE REV. MSS MANAGER MSS PROJECT CLIENT
CLIENT QA/QC
NO. DATE NO. QA/QC MANAGER SUPERVISOR
MICC CABLES
1. PURPOSE
This method statement for MICC cables describes the installation as per project specifications, regulations
in a safe manner to an approved and controlled methodology. The Job Hazard analysis in the appendix
identifies the hazards and the safe systems of work to be followed when conducting the activity.
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2. SCOPE
The scope of this document includes, but is not limited to the following:
a) Methodology for MICC Cables Installation
b) Tools & equipment used
c) Inspection and Test Plans
d) HSE Assessment & Job Hazard Assessment
3. DEFINITIONS/ABBREVIATIONS
HSE Health, Safety and Environment
QA/QC Quality Assurance/ Quality Control
ITP Inspection and Test Plan
WIR Work Inspection Request
PTW Permit To Work
BS British Standard
MICC Mineral Insulated Copper Cable
4. TOOLS AND EQUIPMENT
The following tools and equipment items have been identified for the installation of wiring accessories
and general power system related works:
a. Hand Tools Box (Spanner set, cutting players, screwdriver set, hammer, hacksaw frame & flat file,
cleaning brush, spirit levels)
b. Measuring tape
c. Drilling Machine
d. A-Type Ladder
e. Mobile Type Scaffolding with wheel safety lock
f. Labeling printer
g. Pot
h. Pot Seal
i. Gland
j. Potting compound
k. Pot crimper
l. Stub sleeve
m. Plier
n. Crimper
o. Joistripper
p. Ringing tool
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5. SEQUENCE OF WORKS
The following are the step by step procedures for the installation of light fixtures & wiring devices and
accessories
Prior to installation, it will be ensured that:
a. All relevant documentation such as (Approved Shop drawings, Checklist and Approved Method
Statement for Installation of MICC cables, etc.) and the material applicable to a particular section of work
will be Checked by the Site engineer prior to the commencement of work ensuring that these are of the
correct type as reviewed by the Engineer
b. Before commencement of installation, Material inspection will be carried out prior to being withdrawn
from the storage area i.e. quantity, physical damage and brand/make.
c. Before the beginning of the installation, it will be ensured that the approved valid permit to work (PTW)
is available on site.
d. Engineer in charge will ensure that approval and standard tools and tackles are available to carry out
the work.
e. Safe access to work areas will be provided and will be approved by the competent safety person prior
to commencement of works if applicable.
f. Check the work area tidy and remove flammable materials if any and a safe environment will be
ensured.
g. Where the risk assessment identifies high-risk works a permit to work will be obtained from the safety
department.
h. Competent manpower will be employed to carry out the installation work.
i. Prior to installation, It will be ensured that all the civil works are completed.
j. Necessary Civil clearance will be obtained (if applicable) prior to the start of installation.
6. MATERIAL TRANSPORT
a. MICC Cables and other related accessories will be handled and transported and unloaded at site strictly
as per manufacturers instruction.
b. After delivery, Items will be inspected for any transport both internal and external components casing
damage, in compliance with project specification & materials submittal.
c. Approved shop drawings will be posted at the workplace for site reference used and installation works.
7. DELIVERY AND STORAGE:
a. Upon material delivery, storage and equipment handling will be kept as directed in a neat with safety
precautionary measures according to the manufacturer’s recommendation and in accordance with the
HSE Plan.
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b. Deliveries will be inspected and handled at the site area according to the given instructed
requirements.
c. Mechanical handling will be considered prior to manual handling.
d. When materials arrive at the site will be inspected randomly and ensure that the materials are as per
approved material submittals.
e. Any discrepancies, damage, and etc. found to the materials will be notified and reported to QA/QC
Engineer and Project Engineer for further action.
f. All the material will be inspected and approved by Engineer prior to dispatch to the site and
commencement of works.
g. Materials found not suitable for site use will be removed from the site immediately.
h. While unloading, shifting, and storage, it will be ensured that there are no damages.
i. All delivered materials will be inspected on arrival at the site.
j. All materials will be free from any defects or damages and foreign materials that will result in the
inability to install the materials and subsequent deterioration.
8. HANDLING
a. All materials will be delivered to the site by truck/trailer.
b. All incoming MICC cable drums will be off-loaded on the nearest point of cable pulling start point.
c. When the drum reaches designated areas, the cable drum will be unloaded to the proper cable jack
directly for easy cable pulling operation.
d. After unloading of cable drums, it will be ensured that there is no damage that occurred during
transportation & lifting.
e. Any discrepancies, damage, and etc found to the materials will be notified and reported to QA/QC
Engineer.
f. Materials found not suitable for site use will be removed from the site immediately and moved to the
quarantine zone.
g. On receiving materials at the site, a material inspection request will be raised for Engineer approval.
h. All the materials will be as per approved material submittal.
i. No materials will be permitted to enter the work location without prior inspection and approval.
9. METHODOLOGY
9.1 INSTALLATION OF MICC CABLES
MICC Power cable is a high conductivity copper conductor embedded in highly compacted magnesium
oxide insulation with a robust, ductile copper sheath. MICC Cables are mainly installed in Substations for
electrical lighting and small power systems.
9.2 LAYING OF MICC CABLE
a. All cables will be laid as per approved shop drawings. Instrument and control cables will not be
grouped with power cables.
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b. Minimum bending radius of the cable will be checked prior to cable pulling to avoid exceeding the
bending limit.
c. Cable identification tag will be made available for cable in advance and also after glanding.
d. It will be ensured that the cable ladder/cable trays are free from any sharp edges and are having
sufficient spaces for installation.
e. Visual inspections are performed to ensure there are no sharp edges or burrs that could damage the
MICC cables during installation.
f. Before removing the hoist, the direction of the arrow on the drum will be checked and will be in the
same direction as the pull.
g. The necessary cable roller will be placed in the cable passage and the cable winch and pulling grips
will be connected to the cable.
h. Proper coordination and communication between the workforce will be ensured.
i. When unrolling cable, a plastic or plywood sheet will be provided and laid in-ground for cable
protection and will avoid any scratches and damages to the cable’s outer sheath insulation.
j. Cable roller guides will be placed under the cable during pulling over longer distances and standoff
rollers for acute bends and will ensure that the cable is pulled with minimum effort and cable outer
jacket is free at scouring lines
k. It will be ensured that the cable will not be allowed to twist or rotate about its longitudinal axis during
the pulling process.
l. It will be ensured that the cable will not be bent during installation, either permanently or temporarily
to a radius less than the allowed minimum bending radius allowed by the manufacturer.
m. The cables will be spaced in accordance with the approved shop drawings and tied to the ladder/tray
using approved cleats and or cable ties for both horizontal and vertical run. MICC cables shall be
installed on cable trays and secured to backstraps fixed to the side of the trench. Such cables shall be
saddled to this cable tray at intervals of not more than 500mm as per project specifications.
n. Cables will be installed from terminal point to terminal point and straight through joints will not be
made unless approved. Where a run of MICC cable is of a length that exceeds the maximum which can
be manufactured, a through joint of a pattern agreed with the Engineer will be permitted as per
requirements.
9.3 INSTALLATION OF MICC CABLES IN SUBSTATIONS
a. Before the start of works, it will be ensured that the civil works are completed.
b. It will be ensured that all accessories, tools, and equipment are available before the start of work.
c. All the responsible precautions to prevent damage to the cable from severe blows with sharp
instruments and pulling over sharp objects are taken.
d. The cable will not be pulled around corners that have sharp edges, such as corners in cable trays, or
other obstructions.
e. The cables will be completely uncoiled (if needed) or removed from the reel and laid out in a straight
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run with the end to be pulled closest to the entry point into the support system.
f. The cable will be pulled by hand through the desired routing.
g. When changing the direction from a horizontal to a vertical pull, sheaves or pulleys will be used to
guide the cable around the bend.
h. The surface run cables will be fixed with saddles at intervals of not more than 500mm as per project
specification.
i. Conduct an insulation test on the cable and record the result.
j. Cable will be identified at both ends for proper identification of cable. The marker sign will be the
same as the feeder designation in the cable schedule.
k. Where cable passes through a fire barrier approved fire-stopping material will be provided as
recommended by the Engineer.
9.4 TERMINATION OF MICC CABLE:
a. Cable glands will be brass compression glands and comply with the relevant part of BS 6121, except
for MICC cables, which shall comply with BS 6207 Part 2.
b. Cut the cable off the square. This will be done with a small hacksaw, a ringing tool, or sharp cable
shears.
c. Start the stripped cable by turning the joistripper clockwise down the cable.
d. When the cable is stripped to the desired length, lightly grip the cable with the pliers. Run the
joistripper up to the pliers. This will give a nice clean square cut.
e. Put the gland top, olive, and gland bottom of the cable. Do not tighten it up yet.
f. Screw the pot in the cable until the sheath of the cable is flush with the bottom of the pot. Be very
careful not to twist the cable while screwing on the pot. Then pull the wires slightly apart and test the
wires with an insulation tester.
g. Slightly overfill the pot with potting compound. It is ensured not to touch the compound which could
cause the pot not properly insulated the pot.
h. Slide the pot seal into place, making sure the wires are not twisted.
i. Insert the pot assembly into the pot crimper, it will be ensured that three prongs of crimper are
between where the wires come through the seal.
j. Crimp the pot.
k. Sleeve the wire into stub sleeving and carry out another insulation test to ensure cables are free of
fault. Also need to do the continuity test.
l. Slide the gland into place.
m. It will be ensured that the technicians wash their hands after the installation. Magnesium oxide is not
good for health.
n. After the cable ends are terminated with the permanent seal, the cable should be subjected to IR
(Insulation Resistance) Test.
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10. PERSONNEL
10.1 PROJECT MANAGER
a. Project Manager (MEP) will be responsible to manage, executing, complete and handover the
construction activities within approved budgets and resources in compliance with project requirements
as specified in project specifications. He will be overall in charge of implementing the Method
Statement in accordance with QA/QC and HSE requirements.
b. Responsible for controlling the project’s entire activities & for the overall coordination with the
consultant/client.
c. Ensure that adequate welfare facilities and equipment are provided to the project to avoid injury,
health impairment, or damage & to ensure providing quality works within the planned time scale.
d. All responsibilities stated in the Project’s Quality Assurance Plan.
10.2 CONSTRUCTION MANAGER
a. Organize the site so that work is carried out to the required specifications with minimum risk to men,
equipment, and materials.
b. Coordination with different functions with the project.
c. Expediting area of concern to achieve project schedule.
d. Adhere to the project-specific quality management program and HSE requirements.
e. Delivering the overall works in a safe and timely manner, ensuring conformance with the
approved design. Leading the team of engineers and surveyors, guiding them in the delivery
of the works. Acquire, allocate and maintain resources.
10.3 QA/QC MANAGER
a. Responsible for the work entire quality assurance, quality control & inspection programs
b. Produce all quality-related documents & reports necessary as requested by the
Owner/Consultant/Engineer.
c. Provide written procedures & coordinate in formalizing the Method Statements with the Project
Manager/ Construction Managers/Site Engineers to describe the job-specific work for each
stage/activity.
d. All responsibilities stated in the Project’s Quality Assurance Plan.
10.4 QA/QC ENGINEER
a. Responsible for the work entire Quality Assurance/Quality Control activities & inspection programs.
b. Produce all quality-related documents & necessary quality reports as requested.
c. Provide written procedures & to coordinate in formalizing the Method Statements with the
Construction Manager/Site Engineers to describe the job-specific work for each stage/activity
d. Make sure that all the works mentioned in this method statement will carry out in approved shop
drawing and as per the project specification.
e. Make sure WIR for all these activities are raised and approved by the consultant and record those
documents for testing, commissioning, and handing over the procedure.
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10.5 SAFETY MANAGER
a. Manage Safety Engineers and Safety Officers to be in strict conformance with project policies and
procedures.
b. Ensures safe work method of stated in method statement and risk assessment is fully implemented
during activity.
c. Responsible for controlling HSE personnel for effective monitoring of work.
d. Oversee site safety orientations/inductions, toolbox talks, safety training certifications, job site
inspections, working at heights, scaffolding tagging systems are fully functional, rigging, etc.
e. Report to Project Manager all personal injuries and near-miss incidents (aligned with Safety
Engineers / Officers) as well as property damages immediately. Produce investigative reports and
summaries to senior management.
10.6 SAFETY OFFICER
a. Provide advice and coordination in line with the project HSE Plan, legislation, and standards to
workgroups as required/directed.
b. Input into the preparation and maintenance risk register at the project level which will form the basis
of risk management on the project.
c. Monitoring and reporting compliance with the Project HSE Plan.
d. Conducting regular HSE inspections and participating in HSE audits.
e. Reporting as required, HSE incidents, including near-miss events, injuries, and any other HSE issues.
f. Regularly attending toolbox and other HSE meetings
g. Ensures that the worksite has been examined, and all precautions specified to be taken in the PTW
before work commences have in fact been taken
h. Will ensure that the works are examined on completion of the works and the “Permit To Work” is
correctly closed.
10.7 SITE ENGINEER
a. Adheres to the Project-specific method statements, procedures, inspection programs & HSE
instructions to get the activities performed to client satisfaction with full coordination with the HSE &
quality personnel.
b. Responsible to ensure that correct drawings, materials, tools, and equipment are provided site.
c. Liaising with sub-contractors, supervisors, planners, quantity surveyors send the general workforce
involved in the project.
d. Responsible for planning the work and efficiently organizing the plan and site facilities in order to
meet agreed deadlines.
e. Site engineer is responsible to coordinate with QA/QC Team engineers/ inspectors, and handover
daily site progress works reports/highlighted drawings & presenting during inspection/site visit with
QA/QC Inspectors & consultant/client.
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10.8 FOREMAN
a. Performed the activities that were instructed by the Supervisor/Engineer at the site and follow the
safety procedures to make it safe for his workers.
b. In charge to lead the work execution send the focal point in coordinating with the site
Supervisor/Engineer related to overall site activity, materials, tools, and equipment.
10.9 TECHNICIAN
a. Carry out Installation work as per the concerned foreman’s instructions with all the safety
requirements.
b. The workforce to attend daily toolbox talks, morning task brief briefs prior to starting any works EHS
(Environment Health Standard) plans and policies.
10.10 WORKFORCE
a. Carry out their work in such a way that they don’t create for themselves or any other person risk to
health safety, and don’t impact the environment to the maximum extent possible or affect the quality of
work.
11. QUALITY CONTROL
The Inspection and Test Plan (ITP) for this Method Statement summarizes various characteristics to be
checked. The concerned Site Engineer or Site Supervisor will be responsible to ensure compliance for
these operations and the site QA/QC Engineer will carry out quality control checks and report the
inspection results.
13.QUALITY RECORDS
Quality records will be provided as identified in the ITP and maintained as per ISO 9001/2015 Standard
form of records, quality checklists and QA/QC reports requirements are defined in the Inspection and Test
Plan.
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METHOD STATEMENT FOR
IRRIGATION SYSTEM
SR. EFFECTIVE REV. MSS MANAGER MSS PROJECT CLIENT
CLIENT QA/QC
NO. DATE NO. QA/QC MANAGER SUPERVISOR
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IRRIGATION SYSTEM
1. DESCRIPTION OF WORKS
This Method Statement for Irrigation defines the general procedure implemented for the installation of
the irrigation systems as per project specifications, quality, health, safety, and environment requirements.
1.1. INTRODUCTION
This method statement for irrigation system shall be followed for construction of any particular
irrigation installations including the excavation and installation/laying of main pipeline, lateral line pipe,
valves, and valve boxes, driplines, emitters, sprinkler pipes, etc. It will also include the jointing and
pressure testing of pipes.
The objective is to specify the methodology of works and the requirement in terms of sequence, tools,
equipment, labor, materials, logistics, quality, health and safety, and environment.
This method statement is subject to the requirements as stated in the following regulatory & statutory
documents, applicable standards/specifications/building codes:
Project Specification – Irrigation Specifications, Irrigation System, Pipeline Installation
1.2. DEFINITIONS
QA Quality Assurance
QC Quality Control
MS Method Statement
PQP Project Quality Plan
HSE Health, Safety & Environment
PMCM Project Management – Construction Management
CSC Construction Supervision Consultant
HDPE High-Density Poly Ethylene
LDPE Low-Density Poly Ethylene
PVC Poly Vinyl Chloride
Psi Pound per Square Inch
ITP Inspection & Test Plan
FDT Field Density Test
MDD Maximum Dry Density
INR Notice of Inspection
RLM Red Line Mark-up
AWWA American Water Works Association
ASTM American Society for Testing and Materials
DIN Deutches Institut fur Normung
BS British Standard
ISO International Standard for Organization
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OD Outside Diameter
ID Inside Diameter
PN Nominal Pressure
DN Nominal Pressure
PPE Personal Protective Equipment
Kw KiloWatt
NCR Non-Conformity Report
GPM Gallon Per Minute
LPS Liter Per Second
m/s Meter Per Second
SCH 40/80 Schedule 40/80
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1.3. REFERENCE
Contract Specifications
Project Specification-Specification for Irrigation System
Manufacturer’s Installation Instruction Guidelines
1.4. DUTIES AND RESPONSIBILITIES
PROJECT MANAGER
The representative of the management is responsible for the approval and compliance of the
participating teams in performing this method statement for irrigation system. It is within his
judgment that the executing parties (Construction Team, QA/QC Team & HSE Staff) can attain
proper and safe implementation of this method statement.
He is overall responsible for production quality, program, planning, surveying, testing, safety, and
coordination.
CONSTRUCTION MANAGER
Responsible for overall construction activities ensuring that all quality and safety procedures are
implemented and required approved permits are obtained.
QA/QC MANAGER
In charge of all quality assurance and quality control matters of the project.
Overall responsible to ensure all activities are in compliance to project specifications and approved
ITP.
If any non-compliance he recommends to QA/QC Engineer to initiate internal NCR and coordinate
with the construction team to close NCR.
QA/QC ENGINEER
Ensure the proper implementation of the quality system and monitor the overall quality of the
irrigation work is maintained.
Conduct inspection and monitor tests.
Determine and report any non-conformance and recommended corrective actions.
Ensure that all personnel is aware of the quality requirement.
Training of relevant personnel.
Conduct surveillance and inspection duties at various stages to ensure compliance to QA/QC plan.
SITE ENGINEER
Supervise operations in accordance with the approved method statement for irrigation system, shop
drawings, project specifications, material submittals, and schedules to achieve the acceptance of the
project deliverables.
SITE FOREMAN
Liaise with the site engineer and supervisor for the work execution.
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SITE SUPERVISOR
Supervise closely, the activities designated to them and ensure that all instructions and safety
procedures are followed and strictly adhered to.
HSE MANAGER
Health, safety, and environmental (HSE) manager generally plan, coordinate and implement issues
and directives within the organization.
Ensure safe environmental working conditions for all employees.
HSE ENGINEER
Ensure enforcement of safety procedures in accordance with the approved HSE Plan.
Closely monitor the site engineer’s strict implementation of the method statement for irrigation
system, the use of proper tools and equipment to maintain safety, certifications of equipment and
their adherence to safety regulations, reporting of any unsafe work or stopping work that does not
comply with ES&H procedures.
Advises the health and safety requirements and monitor the Hazard controls implemented on site as
per the method statement irrigation system.
SURVEYOR
Obtain all data and information required for surveys.
Determine methods to establish survey control.
Use appropriate equipment to complete assigned task.
Keep accurate notes and records to describe and certify work performed.
SURVEY AIDE
Assist Surveyors in taking measurements, record measurements manually or electronically, and peg
out boundaries.
EQUIPMENT OPERATOR
The only authorized person to operate any equipment to be used in the project.
THIRD-PARTY LABORATORY TECHNICIAN
Performs the required testing and provides test results to certify that the work is in compliance with
the project and contract requirements.
2. RESOURCES
2.1. PLANT AND EQUIPMENT
Telehandler/Boom
Loader
Crane
Flat Bed Trailer
Forklift
Excavator
Tipper Trucks
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Backhoe Loader
Boom Truck
Mini Excavator
Skid Steer Loader
Generator Set
Tower Lights
HDPE Pipe Butt Fusion
HDPE Pipe Electrofusion Set
Plate Compactor and/or roller
Survey Instruments
Water Tanker
Pick-up
Scaffolding
Movable Ladder
2.2. WORK FORCE
Project Manager
Construction Manager
QA/QC Engineer
Site Engineer
Surveyor
Survey Aide
Foreman
Equipment Operator
Banksman
Pipe Fitter
Helpers/Laborers
Safety Officer
First Aider
Third-Party Laboratory Technician
2.3. LIGHT TOOLS
Power Tools and Pipe
Cutters (Drilling machine, machine, hammer, etc.)
Hand Tools (Hack saw, hand shovel, hammer, spanner set, screwdriver set, pliers, file, knife, wrenches,
etc.)
Test gasket, spades, blank flanges
Pressure Testing Equipment
Pressure Gauge
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
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S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 643 of 864
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MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
FDT Testing Equipment
Nylon Lifting/Slings
Wheel Borrow
Spirit Level
Measuring Tape
String Line
Feeler Gauge
Markers and Masking Tape
2.4. MATERIALS
PVC pipes and fittings ( Solenoid valve, QCV, Air release valve, drain valve assembly locations)
HDPE pipes and fittings
TSE network connection filter and master valve
Solenoid valves
Inline filter on solenoid valve assembly
Geka coupling
Quick Coupling valves
Air /vacuum release valve
Drain Valve
Valve box
Inline drip tube
Online emitter
Drip tube compression fittings
Drip tube stake
Pumping system and accessories (vertical centrifugal pumps, manifolds, isolation valves, non-return
valve, pressure gauges, pressure transducers, level sensors, dry run protection, pressure relief valves,
pressure vessel)
Automatic self-flushing filter
VFD control system
Electric control panel and accessories
Decoder controller and filed decoder
Irrigation control cables and waterproof wire connector
Power cable for irrigation controller and pumping system
Water Meter
Warning tape
Selected backfill and sand bedding
PVC cement and cleaner
Gasket lubricant
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Gate valve
Flange adaptor
S.S. nuts, bolts, and washers
Non-return valve
Ball valve
Concrete
Chamber cover
Level sensor
Pressure sensor
3. SITE PLANNING & PREPARATION
a. Works shall be carried out under the supervision of the Site Engineer, Safety Officer, and QA/QC
Engineer.
b. Work to be carried out in line with approved Site layout drawing relevant to the area and the required
trial pit related to the excavation must be inspected, verified by the consultant prior to trench excavation.
c. Traffic will be managed by the Site Engineer/ Site Supervisor and the Safety Officer for any re-routing as
well as the monitoring of equipment movements on site, transporting foundations, and lifting area.
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d. Working area will be protected with plastic jersey barriers, safety signage, and safety tapes. Existing
Structures, Utilities, Sidewalks, Pavements should also be protected.
e. Any MEP or any other underground utilities required clearance shall be obtained prior to starting the
activity.
f. Ensure that sufficient tools, materials, and manpower are available before commencing the work.
g. All relevant documentation (approved shop drawings, checklists, method statement irrigation system,
material sample for pipes, fittings, and solvent cement/adhesives, etc.,) and materials applicable for the
particular section of work will be checked by the Site Engineer/Supervisor prior to commencement of
work.
h. The Site Engineer/Supervisor will give necessary instructions to the tradesman and provide the
necessary approved shop drawings.
i. Materials shall be delivered in their original, tightly sealed containers or unopened packages, all clearly
labeled with manufacturers name, brand name, number, and batch member of the material where
appropriate.
j. The material shall be delivered to the site in ample time to avoid delay in the job progress and at such
times as to permit proper coordination of various parts.
4. WORK METHODOLOGY-METHOD STATEMENT FOR IRRIGATION SYSTEM
4.1. PRELIMINARY ACTIVITIES AND APPROVALS
a. All necessary work permits (excavation, hot works, cold work permit for pressure test, temporary road
closure, etc.) shall be obtained prior to commencement of works on-site and shall remain valid
throughout the entire duration of the operations.
b. Excavation permit to be obtained for each area of excavation.
c. Check for existing utilities before excavations.
d. Road Closure (if applicable).
e. All interfacing activities shall be fully coordinated with the Supervision consultant.
f. Take proper measures to protect the joint from sand, rain, and direct sunlight.
g. CAT scan/trail pit to detect any existing utility services.
h. Material approval
i. Shop drawing approval
j. Approved method statement for irrigation system, checklist, inspection, and test plan.
k. Physical site verification to check all grades and determine that work may safely proceed, staying
within the specified material depths.
I. Mockup approval.
m. Labor welfare facilities (shelter, toilet, cool drinking water, first aid, etc.)
4.2. PRE-CONSTRUCTION ACTIVITIES
a. Calibration of equipment, gauges, etc.
b. Dust control, all existing facilities protection
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c. Interface coordination between other disciplines shall be coordinated. Elevations, pipe routings will be
determined by utilities and above-ground obstructions. Revised locations and elevations from those
indicated as required to suit field conditions shall be submitted for approval.
d. Site warehouse/store room-material and equipment shall be stored in separately marked approved
warehouse /storeroom/laydown areas. Designated warehouse /storeroom/laydown area should comply
with the requirement of proper storage of materials and equipment as per manufacturer/supplier and
project specification for materials
/equipment storage.
e. Site management plan and access route-upon receiving approved shop drawing, all excavation
routes /locations will be set out and marked routes plan and access shall be divided by geographical
zones. The information will be provided to the construction team for implementation.
f. Coordination with other contractors. The marked-out routes will identify the interface coordination
which will be communicated with other contractors on site. The interface coordinator will be
responsible for coordinating with other facility contractors. Coordinating with other related activities
and other trade disciplines shall be the responsibility of the site engineer.
g. Traffic management-The required diversion routes will be marked on drawings including the required
traffic signs.
Communication-Communication on site will be by GSM mobile phones. In case of emergency,
announcements will be made through a portable public address system or air horn to evacuate people
to designated areas.
h. Safety precautions shall be prepared.
• Checks the protective and safety equipment are ready.
• Personnel protective and safety equipment shall be performed.
• PPE shall be used by the person doing the task.
• Toolbox talks to be convened and attended by personnel assigned to the job. The work crew will be
given instruction on safety works procedures and all risks associated with the task and registered
attendance.
• PPE, signage, barricades, safe access, and egress to the work area.
• Safety personnel and designated responsible person will ensure that the above-mentioned is carried
out and any other statutory requirements are compiled before the start of any work.
4.2.1. MATERIAL DELIVERIES, HANDLING, STORAGE & PRESERVATION
Each pipe, fitting, and special appurtenance for irrigation system shall be marked with permanent
identification which shall include but not necessarily be limited to the following:
(a) Nominal diameter
(b) Name or trademark of the manufacturer
(c) Serial number
(d)Class of pipe, pressure rating in compliance with referenced standards
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(e) Date of manufacture
(f) Type of service
(g) Details on fittings such as angle of change and taper
The acceptability of the pipes on delivery to the site will be based on the
results of tests carried out by one or more of the following:
(a) The manufacturer at the place of the manufacturer
(b) The consultant/inspector
(c) A third party on behalf of the consultant.
The consultant/inspector shall be permitted at all reasonable times to visit places of manufacture to
witness tests.
Transport, handling, and storage of irrigation pipes and fittings shall be carried out as follows:
(a) In accordance with the manufacturer’s recommendations subject to the approval of the
consultant/inspector.
(b) Effective precautions shall be taken to prevent damage to the pipe and fittings
During transportation
(a) Pipes and fittings shall be well-secured and adequately supported along their length.
(b) Bolsters and binding of approved type shall be used.
(c) Nesting of pipes (placing a smaller pipe inside a larger) may be permitted pipes of certain materials
and size provided that methods statements demonstrate that effective precautions will be taken to
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protect all pipe surfaces and coatings from damage.
(d) No pipe shall overhang the end of a vehicle.
(e) Pipes and fittings of plastic materials shall be covered.
Handling shall be carried out as follows:
(a) Pipes should be lifted singly and not handled as bunches.
(b) Pipes shall be handled only by means of:
(i) Approved hooks, of the type having a plate curved to fit the curvature of the inside of the pipe, on
ends of sections
(ii) Fabric slings not less than 250 mm wide
(iii) Other methods approved for the pipe used
(c) Use of wire rope, chains, and forklift trucks will not be permitted.
(d) For strings of pipe longer than the standard length precautions shall be taken to avoid curvature and
longitudinal stress in excess of allowable limits.
(e) Pipes and fittings of plastic materials
(i) Smaller than 300 mm diameter may be handled manually
(ii) Larger than 300 mm diameter and greater than 4 meters in length shall be lifted using fabric lifting
straps or large diameter rope slings positioned at a quarter of the pipe length from each end.
(iii) There should be enough slack in the slings to stay the hook. Approximately 600 mm over the pipe
(iv) Steel chains or hooks shall not come into contact with the pipe.
(g) Pipes and fittings shall not be dropped or bumped.
(h) Pipes shall not be dragged over the ground.
(i) If rolled, pipes shall be rolled only over adequate timber bearers to prevent damage.
j) Where necessary, chocks shall be used to prevent lateral movement of pipes.
All pipes, fittings, and materials shall be stored in accordance with the manufacturer’s recommendations
and the following:
(a) Pipes shall be stored in the open on a flat level area and raised above the ground on timber bearers
so that the lowest point of any pipe or fitting is not less than 150 mm above the ground and shall be
protected properly.
(b) timber bearers not less than 200 mm wide and 75 mm thick to be provided at 4 m intervals
maximum. Pipe shall be stacked one above the other as follows:
(i) In accordance with the manufacturer’s recommendations but not to a greater number of tiers than
the following:
< 600 mm diameter 4 tiers.
(ii) Suitable protective packing shall be placed between tiers to the approval of the consultant/inspector.
(iii) Wrapped pipes shall not be stacked.
(c) Spigot and socket pipes are stacked in such a way that successive pipelayers have sockets protruding
at opposite ends of the stack.
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(d) With pipes of different sizes and thicknesses stacked separately.
(e) With a maximum height of stacked pipes not exceeding 2 m, or that recommended by the supplier if
less than 2 m.
Storage of jointing materials shall be as follows:
(a) Undercover
(b) Rubber ring gaskets shall
(i) be stored in their original packing
(ii) not be exposed to sunlight
(iii) be protected from exposure to greases and oils
(c) Gasket lubricants shall be stored so as to prevent damage to the container.
• Pipes and fittings shall be protected in storage to the approval of the consultant by means of an
impermeable membrane which shall cover the pipes and separate them from the ground on which they
are supported.
The membrane shall be strong and durable in the prevailing climate conditions.
• Pipes and fittings shall be subject to visual inspections after off-loading at the site and before
Installation.
• The following procedures shall be followed for dealing with damaged pipes and fittings:
a. Pipes damaged during transportation handling and storage shall be set aside and the damage brought
to the attention of the consultant/inspector.
b. Pipes or fittings that show signs of corrosion or deterioration during storage shall immediately be
treated to arrest and prevent the corrosion or deterioration or removed from the site, as the consultant
directs.
c. Proposals for repair shall be submitted in writing for the consultant’s approval.
d. No attempt shall be made to repair the damage without the consultant’s approval.
e. If in the consultant’s opinion the nature of any damage is such that the condition of the pipe has been
impaired and cannot be repaired the pipe concerned shall not be incorporated in the works.
f. All rejected pipes shall be immediately removed from the site.
g. Damaged pipe shall be replaced or repaired by the contractor at his expense and such repairs shall be
to the approval of the consultant.
Note: Material delivery inspection request is to be raised and to be submitted to the consultant for
inspection for every approved irrigation material delivered to the site.
4.2.2. PRESERVATION OF MATERIALS
Preservation application shall be basically as per manufacture recommendation. Any material found
without required preservation shall be noted in the inspection report.
The material controller shall arrange with the supplier for the proper preservation application or shall
make arrangements for in-house application on a back chargeable basis. No material shall be stored
without proper preservation.
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• Fittings, flanges and valves, warning tape, flow sensor, disc filter, pump set and accessories, electrical
items, controller and accessories, valve boxes, stud bolts, nuts, washers emitter, shall be stored in a
covered warehouse. The identification tag shall be hung on the item/ pallet as on which the material is
stored.
• Flanges stored on wooden pallets, as far as possible, should have their face pointing down, to avoid
damage to the flange face and reduce chances of corrosion.
• Flange faces shall be protected with purpose-made caps or covers wherever possible.
• All pipes shall be segregated according to grade and size when stored. Pipes stacked on wooden blocks
shall be in such a way that they are separated from each other horizontally as well as vertically. All pipe
ends shall be closed with temporary caps or blinds.
• Weekly scheduled visual checks, of the stored items for preservation maintenance, shall be conducted
by the store supervisor along with the material inspector. These visits shall be logged in a register
maintained at each store.
4.3. SETTING OUT
a. Surveyor shall establish all control reference points and delineate the centerline of excavation. The
width and depth of the excavation shall be marked as indicated in the drawings.
b. Verify all horizontal and vertical site dimensions prior to staking.
c. Stake out the location of all pipework, valves, and other irrigation works.
d. The proposed alignment of the pipeline shall be set out by staking out the locations of manholes,
chambers along the centerline of the carrier pipes.
e. Supervising consultant shall be notified of the setting out in sections of routes as mutually agreed and
formally requested for a physical inspection by the submittal of an NOI (Notice of Inspection) which,
shall be (accompanied by a drawing marked up with obstructions wherever they exist.
f. The setting out shall be completed once the Supervising Consultant issues his acceptance. To the
alignment approving the NOI and signing off the accompanying drawings, if any.
g. Ground condition level shall be recorded, inspected, and approved.
h. Before starting work on the irrigation system, the contractor carefully checks all grades to determine
that work may safely proceed.
4.4. TRENCHING AND EXCAVATION
a. Trenching will be carried out by mini-excavator and/or manually by hand wherein there are
underground services to avoid damage to underground services and will be excavated as per the
approved irrigation detailed shop drawing.
b. Irrigation sleeves/ducts under footpaths and roads shall be exposed and verified as well as all services
in the adjacent areas.
c. Excavation and backfilling shall be in accordance with detailed drawings;
• Mainline shall be placed at 700mm deep and warning tape at 300mm above the crown of the pipe
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• Lateral lines shall be placed at 400mm deep without warning tape above.
• Width of the trench should be as shown in the approved shop drawing.
d. Dune sand bedding layer of a minimum of 50mm is required under the irrigation pipe.
e. Sand surround to a minimum of 100mm around the irrigation pipe is required.
f. During excavation topsoil and subsoil shall, as far as is possible be separated and stored on
groundsheets.
g. For the mainline, the trench depth shall be 700mm plus pipe diameter plus 50mm sand bedding. For
the lateral pipes, the trench depth shall be 400mm plus pipe diameter plus 50mm sand bedding.
h. The bottom of the excavation shall be surveyed to confirm whether the reached grades are as per
levels indicated on the shop drawing.
i. Before spreading the sand bedding, ensure that the trench bases shall be level and free of sharp,
irregularly shaped objects and debris.
j. Bedding for pipes shall be constructed by spreading and compacting sand bedding material over the
whole width of the pipe trench. After the pipes have been laid, additional material shall, if required, be
placed and compacted equally on each side of the pipe, and where practicable, this shall be done in
sequence with the removal of the trench supports. Joint holes can be excavated in the bedding but
under no circumstances must the bedding be excavated at any other point along the length of the pipe
barrel without written permission from an engineer.
k. Any pipe found “bridging” at any point will be removed and the bedding made complete and re-
complete to the correct level.
I. Excess spoil shall be removed to an agreed on-site storage area as work progress.
4.5. SLEEVES AND DUCT INSTALLATION
a. When appropriate (asphalt crossing ducts), the excavation for the road crossing and laying of ducts,
concreting, and related work shall only be carried out on half the width of the road at one time, the
other half being left available for traffic. In this case, necessary warning signs on self-supporting tripods
or cones shall be provided well ahead of the
duct crossing works and all care and attention exercised to avoid the risk of accidents during preparation
and execution of the works.
b. Setting out, the excavation shall be carried out is as per the above-mentioned method (setting out
and trench excavation and bedding)
c. Prior to installation of sleeves/ducts the trench preparation shall be checked for the required
elevation, slope, and free from rock, stones, and other deleterious materials.
d. The sleeve shall be inspected for the size required as per the approved drawing and also for
distortion, damages, etc.
e. Ensure all the control measures stated in the corresponding risk assessment are adhered to when
carrying out the job.
f. Road crossing duct shall have a minimum of 150 mm diameter.
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g. All dual systems shall be installed so that no undue strain is placed on cables when pulled in. The cable
manufacturer’s recommendation shall be followed.
h. Duct runs crossing the roads shall be straight and wherever possible perpendicular to the axis of the
road. Road crossing duct shall be extended beyond the road or shoulder line at each side of the road.
i. All carriageway road crossing and for heavy vehicle traffic, the ducts shall be completely surrounded
with concrete of grade C20 SRC concrete/as per project specification. Minimum concrete cover around
the sleeve/duct shall be 100mm.
j. Duct shall be laid so as to drain naturally towards one or both ends, where adequate provision for
drainage shall be made. Adequate precaution shall be taken to prevent the cable duct system from
acting as a stormwater or groundwater drainage system.
k. Spare sleeves shall be laid as per project specification and engineer’s requirement.
I. To prevent earth blocking the ducts, the openings at both ends are to be protected with appropriate
blanking caps.
m. A steel draw wire or nylon or polypropylene cord shall be inserted in each duct run immediately after
its installation. A two-meter surplus length shall be left at each end of each run, neatly coiled and
attached to the crossbar preventing the wire or cord from being drawn into the duct.
4.6. INSTALLATION OF HDPE IRRIGATION MAIN LINES
a. Excavate trench for the mainline having a 700 mm cover min. (top of the pipe to the finished level)
and having a width based on the pipe size.
b. Trench shall be clean and free from unwanted materials.
c. Spread the sand bedding in the trench 50 mm from the compacted subgrade/formation level.
d. Lay the mainline pipe along the center of the trench leaving the joints exposed.
e. Pipes shall be laid to line and grade shown on the drawings.
f. Spread the sand surround to the pipe, according to the project specification and shop drawings.
g. On top of the sand surround, backfilling shall be done layer by layer not exceeding 250 mm
unconsolidated thickness compacted to 95% MDD.
h. Please see Figure 1 below for the typical section of laying of the HDPE main pipeline.
4.7. HDPE PIPE FUSION WELDING
Jointing Procedure
HDPE pipes shall be joined by Butt fusion/ Electro Fusion methods following manufacturer procedures.
Pipe joining shall only be carried out by vendor-trained and certified personnel.
4.7.1. BUTT FUSION METHOD
The most widely used method for joining individual lengths of large diameter polyethylene pipe is by
heat fusion of the pipe butt end .as shown in the figure. This technique precluded the need for specially
modified pipe ends or couplings to produce a permanent and economical and flow-efficient connection.
Field-site butt fusion may be made readily by trained operators using developed butt fusion machines
that secure and precisely align the pipe ends for the fusion process.
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4.7.2 ELECTRO FUSION WELDING METHOD
Electrofusion welding works shall be carried out according to the polyethylene pipes & fittings technical
catalog prepared in accordance with DVS 2207 (Internal standard) and the manufacturer’s
recommendation.
This technique permits the joining, of pre-assembled pipes, to be carried out with minimum equipment.
The electro-fusion welding process involves the use of fitting. This basically an outer sleeve which the
two pipe ends slide into. An internal stop prevents the pipe ends from the meeting.
4.8. HYDROSTATIC TESTING OF MAIN PIPE LINES
a. Hydrostatic testing will follow the manufacturer recommended procedure for the HDPE pipeline
hydrostatic test/as per project specification, Type 1 Creep Test shall be used for HDPE pipes.
b. The section of the main pipeline to be tested shall be filled with TSE water and all air expelled. After
the pipeline has been completely filled, the pressure shall be steadily and gradually increased until the
specified test pressure has been reached. A pressure test shall be made at 150 % of working pressure at
the point of test, but not less than 125% of normal working pressure at the highest elevation. No
pressure drop for 4 hours at pressure test of 1.5 times the maximum working pressure of 9 bars without
exceeding pressure rating of the piping system. All testing shall comply with AWWA M23-80, Polyvinyl
Chloride Pipe Design and Installation. Testing shall comply with AWWA specifications and requirements.
The disposal of the used water in hydro testing & water flushing should be carried out in the appropriate
manner and subject to the approval of the engineer.
c. Instrumentation Calibration: Instruments shall be calibrated within six months from the date of
calibration by the performing calibration and testing agency.
d. Calibration certificate for meter, gauge, fitting, specialty, and accessory meters used for the testing
procedure according to manufacturer’s written instructions to be attached.
4.9. MAINLINE FLUSHING
On completion of the system hydrostatic test, the system is to be thoroughly flushed, the velocity of
water being at least lm/s. Should the main water supply be unavailable or inadequate for this purpose at
the time of flushing, then a swab of adequate size shall be used to remove all foreign matter from the
pipeline.
This process shall continue until the pipeline is completely clean. Each control valve shall be opened
separately and the terminal systems also thoroughly flushed.
4.10. INSTALLATION OF CONDUITS AND CONTROL CABLES
a. UPVC Conduit pipe will be laid in a straight line along with the irrigation main lines above the crown of
the pipes.
b. Pull box to be provided for every 50m to 100m straight line of the pipe or each bends/change in
direction to facilitate easy cable pulling.
c. The solvent cement to be applied to clean, dry surfaces in sufficient quantities to ensure bonding.
d. Long sweep elbows are to be used at bends.
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 654 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
e. Pull wire shall be installed in the conduit.
f. During the installation, the cable drums turning or rolling will be slowed down or stop by wooden
friction brakes so as to prevent the turns of the drum from becoming loose and scrapping on the floor.
g. Splicing using 3M wire connector: Firmly grasp wires, making sure installation ends are even and
tightly bundled. (Wires may be twisted or untwisted). Lead stranded wires slightly. Slip the connector
over wire tips. Turn connector onto wires in clockwise direction until secure
h. Signal cable shall be installed in such a manner that ensures that it is not stretched
/scraped/damaged/laid down under tension.
i. All cable joints will be made ensuring that at least one meter of cable is slack.
j. All cable joints shall be housed in a chamber/pull box.
k. All the wire connections/splices shall be waterproof.
I. Cables inside the conduit shall be loose for easy installation, operation, and maintenances.
m. Cable shall be laid to a minimum depth of 600mm in mainline trench lines and 400mm in lateral
trench lines (where required, and where possible)
n. The signal cable does not lie directly adjacent to any 240V/415V power cable or another
communication cable.
o. Crossing of signal cable at right angles should be avoided wherever possible. However if necessary,
cables should clear each other by approximately 100mm and maintain minimum cover.
p. Signal cable shall be tested during the installation to ensure that there is no earth leakage and that
continuity is present.
q. All power supply cables shall be steel wire armored and where necessary shield cables or ducts will be
provided.
r. All electrical supply works carried out to local bylaw acceptance and shall conform to state /local
safety directives, including voltage drop and test certificates.
4.11. INSTALLATION OF IRRIGATION CONTROLLER, EARTHING AND SURGE PROTECTION
a. Control equipment shall be installed exactly as per manufacturer specification.
b. Controller shall be secured to a concrete pad with approved anchor bolts. Chipping, cracking, or
otherwise marring the finish of the enclosure when securing to the concrete pad shall be avoided.
c. Earthing and surge protection shall be included as per manufacturer recommendation.
d. All electrical works from the power supply to the distribution point shall be carried out inclusive of
necessary cables and switch fuses -all to IEE regulations.
e. Programming of Irrigation Controller: Using the controller schedule provided on the drawings, as a
guide, the irrigation controller shall be programmed to correspond with the initial irrigation sequencing
and duration of the cycles for each zone.
f. Irrigation schedule has to be modified to achieve a correct irrigation regime during establishment and
maintenance in accordance with good horticultural practice, such modification shall be approved by the
engineer.
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FORMATE ID:
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Page 655 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
g. Drilling of earth boreholes.
Place a ground rod in the drilled hole. Copper bonded rods will be conjoined with threaded couplings as
necessary to reach the required depth.
After the rods have been driven to the correct levels, connect the earthing rod using bolted and clamp-
type connectors, and interconnection will be done as per approved drawings. Take a measurement of
the earth resistance value with the drill submerged in the drilled hole.
After all the connections have been completed, backfill until the test level. Perform tightness test for all
connections.
Surge protection will be mounted to the Irrigation controller as per the manufacturer’s
recommendation.
4.12. IRRIGATION PUMPING STATION
The pumping station manifold shall be skid mounted. It shall feature multistage centrifugal pumps.
All necessary ancillary equipment (nonreturn valves, isolation valve, pressure relief valve, pressure
vessel, pressure gauges, pressure transducers, dry run protection, etc.) shall be included in order to
ensure the correct operation of the pumping station shall be provided.
All necessary hoisting and offloading points shall be included on the pump station skid.
Suction shall be from a dedicated water storage tank.
Will liaise with the GRP tank manufacturer regarding the suction pipe works arrangement and follow all
materials to facilitate complete and proper installation.
The delivery manifold shall include a water meter and self-flushing automatic filter the emitter/inline
drip system required filtration size. An automatic filter water meter shall be installed according to the
manufacturer’s recommendation.
Manifold shall be manufactured in 316-grade stainless steel or approved equal.
Butterfly isolation valve shall be incorporated on both suction and discharge manifold to enable isolation
from the water supply /feed into the irrigation mainline.
A pressure relief valve shall be installed on the discharge line with pipe works back to the water storage
tank to release the excess pressure above the operating pressure.
The pump arrangement shall be managed by a variable frequency drive which shall maintain a constant
pressure at a variable flow rate.
To install the pump station/assembly underground/basement, if necessary, it shall be dismantled and
reassembled to effect full installation.
Will make provision to liaise with the main contractor undertaking the pump room fit-out regarding
ingress/egress/ducting/ ventilation/drainage and installation of the tank.
Installation
Examine the condition of substrates and areas to receive irrigation pumps and manifolds for compliance
with the requirements for installation tolerance and other conditions affecting the performance of all
plumbing equipment.
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Page 656 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
Examine rough-in for piping systems to verify actual locations of piping connections before pump
installations.
Check and verify the actual site condition before proceeding with the installations.
Prepare all the tools and equipment that will be required during the installation process.
The connection of the pipe must be carried out with utmost care; otherwise, the pumping medium can
escape during operation, which can seriously endanger the operating personnel.
In a new installation, great care should be taken to prevent dirt, scale, welding beads, and other items
from entering the pump. The suction system should be thoroughly flushed before installing the suction
strainer and suction piping.
Suction and discharge piping should be of ample size, be installed in direct runs with minimum bends.
Short radius elbows shall be avoided near the suction nozzle. If an elbow is necessary, it should be of the
long radius type.
Suction and discharge piping configuration should be in accordance with the manufacturer’s
recommendation.
Suction and discharge piping, fittings, and valves must be adequately supported and anchored close to
the pump flanges to eliminate strains imposed on the pump casing, prevent excessive nozzle loads,
maintain pump/driver alignment and avoid pipe induced vibration.
Check whether the piping is loosely laid so that no strain is placed on the pump.
Piping layout and installation shall provide adequate maintenance and operation accessibility.
Filed installed auxiliary equipment shall not interfere with the removal of the machine or driver.
Remove the covers of the pump flanges. Check whether the seals are correctly mounted.
Install a check valve and isolation valve in the discharged pipe. When the pump is stopped, the check
valve will protect the pump against excessive back-flow pressure and will prevent the pump from
running backward.
The check valve should be installed between the isolation valve and discharge flange in order to permit
its inspection.
A spool piece should be installed in the suction line so that the suction strainer may be installed and
removed with a pressure gauge between the strainer and pump.
Pump and pipe flanges must be parallel; they should mate together without effort, and with the bolt
holes properly in line.
Make sure that there are isolation block valves at the pump of each type of auxiliary piping.
Considering a slope in the suction piping to avoid high points.
In horizontal suction, line reducers should be eccentric (with the flat side of the reducer on top).
No obstruction within at least five pipe diameters of the suction should be fitted.
Do not install unsupported piping on the pump.
Make sure electrical connections do not impose any stress on the pump unit.
4.13. WATER STORAGE TANK
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Page 657 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
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GRP sectional water storage tank (please see example photo below) will be constructed according to
manufacturers recommendation with a dimension of 10m x 7m x 2m high as per approved shop drawing
with a minimum inflow of 14m3/hr.
Before the installation of the GRP water tank, the concrete plinth should be completed first.
a. Skid Base
Once the construction of the concrete plinth is completed, the skid base needs to be installed or placed
on top of the concrete plinth. The skid base is made up of two elements; that is the main beams and the
sub-beams. The main beam is made of I-beams or C-channels and the sub-beams are made of equal
angles and C-channels.
The main beams are placed across the top of the RC plinth 1002mm center to center. The sub-beams are
placed across the main beams 1002mm center to center. They are bolted to the main beams. The skid
base must be tightened using HDG bolts & nuts.
The skid base should be leveled.
The top surfaces of the main and sub-beams should be flush.
The skid base should not be twisted and the deviation between diagonals should be as small as possible.
b. Base Panel
Arrange the Base Panel according to the drawing of “General Arrangement for Panel Type and Drill
Code” which is provided with every tank shipment.
Place corner patch (Foam Sealant) at all the four- (4) corners of each panel.
Then put a strip of Foam Sealant in between each panel.
Then place M10 x 45 bolts & nuts to join the panels to each other.
Repeat this process until all Base Panels have been joined.
Corner patch (Foam Sealant) at all 4 corners of each panel.
c. Wall Panel
Proceed with the installation of wall panels. Arrange the wall panels according to the drawing of
“General Arrangement for Panel Type and Drill Code”. All the wall panels are hoisted onto the structure
and installed on the structure.
Corner patches are placed at all angles of each panel.
Strip with foam sealant is then placed between each panel (horizontal and vertical).
For horizontal flanges of the wall panels, they have to be joined together with M10 x 45 bolts & nuts and
frame angle.
For vertical flanges, the panels are joined together by using frame angle at the joints and M10 x 45 bolts
and nuts to tighten.
After installing all four sides of wall panels, one part column of the wall panel must not be erected. This
portion is for access purposes, i.e. to install accessories, roof supports, and roof panel,s and to prevent
damages to the other panels.
d. Roof Panel
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NAME OF CLIENT: KAMOA COPPER S.A.
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Arrange the roof panel and manhole cover according to the drawing of “General Arrangement for Panel
Type and Drill Code”.
Then put a strip of foam sealant between each panel.
Connect the roof panel and the top side of the wall panel using HDG.
e. Finishing
Installing tie rods/HDG external reinforcement-Refer to tie rod arrangement/external reinforcement
drawing provided with the tank shipment.
Close up the access (same as the wall panel process).
The water level indicator is connected to the bolt of the top tier and the bottom tier of the wall panel.
Drill one no. of 12mm holes for the nylon string to be laid. The nylon string is to be tied to a float ball
and indicator pointer.
The internal ladder is to be installed exactly at the access manhole and the top of the ladder is to be tied
together with the HDG bracket at the roof panel. The bottom parts of the ladder use stainless steel
brackets and tighten them with stainless steel bolts and nuts.
To Install the external ladder, drill two nos of 12mm holes at the top of the wall panel and align with the
access manhole. Then tighten the ladder using HDG bolts and nuts. The bottom parts of the ladder use
HDG brackets and tighten them together to the bottom tier panel.
For pipe connection, the hole location is to be marked (by others); Hand drill or hole saw (for small bore)
and jigsaw (for large bore) are to be used to drill the hole according to the markings. It is recommended
to drill the panel from both sides in order to ensure smooth edges.
4.14. TRENCH BACKFILLING
a. Once mainline levels are satisfactory, sand surround will be spread and compacted lightly using hand
tampers on both sides of the pipes and 150mm above the pipe.
b. Backfilling shall not be commenced until Installation of the pipeline/duct/ cable conduit and
associated pipe joints have been carried out.
c. Backfilling shall not be commenced until the parts of the works to be covered have achieved strength
sufficient to withstand all loading imposed thereon.
d. Backfilling shall not be commenced until successful pipeline pressure testing shall be conducted.
e. For backfilling, selected backfill material shall be used above the pipes. The backfill shall be with a
suitable friable material, free of large stones and sharp objects.
f. Selected backfilling material shall be used to backfill the trench. Backfilling material shall be deposited
by 250mm thick layers and compacted with compactor (manual/mechanical) as per site condition.
Compaction shall be 90% MDD as per project specifications.
4.15. INSTALLATION OF WARNING TAPES
a. Trench marker tape/warning tape shall be laid 300mm above the mainline pipe.
b. The tape shall be laid continuously over pipelines and at joints and there shall be a minimum of one-
meter overlapping.
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FORMATE ID:
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Page 659 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
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c. Tape shall be terminated inside valve boxes to allow clipping of detector equipment to the tape.
4.16. INSTALLATION OF HDPE IRRIGATION LATERAL LINES
a. Excavate trench for the lateral lines having a minimum of 400mm cover (top of the pipe to the topsoil)
and having a width based on the pipe size.
b. Trench shall be clean and free from unwanted materials.
c. Spread the sand bedding in the trench minimum of 50mm from the compacted subgrade/formation
level as per project specification and approved shop drawing.
d. Lay the lateral line pipe along the center of the trench leaving the joints exposed.
e. Pipes shall be laid to line and grade shown on the drawings.
g. Spread the sand surround to a minimum of 100mm around the pipe, according to project specification
and approved shop drawing.
h. Lateral lines with diameters of less than 90mm will be jointed by compression fittings as stipulated in
the Project Specification.
i. On top of the sand surround, backfilling shall be done layer by layer not exceeding 250 mm,
unconsolidated thickness up to the finished level for hardscape areas.
k. Under the soft landscape area, the backfill material shall be soil planting mix and it shall be water
compacted.
l. All necessary wall/planter/paving penetration shall be identified and shall be ducted.
m. Pipeline installed within paving areas (between slab/paving etc.) must be ducted in position.
4.17. VALVES INSTALLATION AND VALVE CHAMBERS
4.17.1. GENERAL
a. Valves will be installed in positions at the location shown on the drawings, as per the manufacturer’s
recommendations.
b. All remote control valves, manually-operated gate valves, quick coupling valves, air release valve, and
flush valve shall be tagged and identified. All identifying numbers shall be consistent with like
designations indicated on the irrigation controller schedule.
c. Valves shall be assembled neatly and installed so that they are accessible by hand to carry out
maintenance.
d. TSE network tie in connection points with necessary filtration and connection point master valve shall
be provided.
e. Test and flush each line prior to valve installation.
f. All valves shall be checked for defects or damage.
g. All valves shall be thoroughly cleaned internally immediately prior to installation and all ends shall be
kept closed with protective coverings when the valve is not being worked upon.
h. All installations should be neat and tidy.
4.17.2. REMOTE CONTROL VALVES
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Page 660 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
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a. Solenoid Valves shall be incorporated into an irrigation chamber.
b. Valves shall be installed in one chamber or as indicated in the approved shop drawing. Chambers shall
be installed at a suitable location away and not in the way of either pedestrians or maintenance
machinery.
c. The solenoid valve shall not be installed within 40mm of the top of the valve chamber; all products in
the chamber shall be easily accessed and a mock-up shall be provided for approval before installation.
4.17.3. ISOLATION VALVE
a. Isolation Valves should be protected from damage during transportation, loading, and handling.
b. Lifting by means of any lifting device should only be done using the flange holes, lifting eyes, or
appropriate straps. Never suspend the valve in a handwheel, gearbox, or actuator.
c. Before installation, a visual check must be performed. Special attention should be paid to checking the
system, valve seat area, flanges, and coating. Look for defects, bent or out-of-place parts, dents,
scratches, and other damages. Actions should be taken to repair or replace the valves if any defects are
detected.
d. Bolts must be tightening in a criss/cross pattern. Actions should be taken to ensure even pressure on
the gasket surface.
e. All valves shall be installed within appropriate irrigation chambers and c/w Denso tape coating or
equal corrosion inhibitor. All flanges shall be stainless steel 316 grade.
4.17.4. VALVE BOXES
a. All valve boxes shall be installed as detailed and where indicated on drawings. All valves and valve
assembly shall be set parallel with the grade and as detailed in a neat and orderly fashion.
b. Shall be placed parallel to paving, kerbstone, walls, or similar structures and where more than one
box, parallel to each other.
b. All valve boxes will be installed with concrete blocks preventing the load of the chamber and
associated traffic from touching the pipelines.
c. All chambers will have a textile membrane installed at the chamber base with 50mm pea gravel.
d. Signal cable will be clipped to the chamber to prevent obstruction of the products within the
chamber.
e. Chambers shall be corrosion resistant, supplied with a lockable cover.
f. Be suitably sized to enable easy access to all equipment and allow a minimum of 40mm clearance of
valve chamber lid above the manual watering point.
g. Valve lids shall be lockable and vandal resistant and mark nonpotable.
h. Where installed in hard paving, the chamber lid/chamber shall be a specialist product that enables
the paving stone/slab to be inset.
4.17.5. QUICK COUPLING VALVE
a. Quick coupling valve size shall be 1″.
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b. Each valve shall include an isolation valve within the assembly.
c. QCV shall be firmly fixed to riser pipe with 100mm thick concrete base.
d. Round valve box shall be installed on the concrete base.
e. Valve assembly shall be easily accessible for operation and maintenance.
f. Swivel, key, and garden hose shall be provided for every 8 nos. of QCV installation.
4.17.6. AIR RELEASE VALVE
a. Air valve shall be installed at the highest point of installation.
b. Valve shall be 2″
c. Each valve shall include an isolation valve within the assembly.
d. Valve assembly shall be easily accessible for operation and maintenance
4.17.7. DRAIN VALVE-MAINLINE
a. Drain valve shall be 2″ in size.
b. Pipe shall be extended approximately 8 meters beyond the valve chamber to into a suitable drainage
material/flooding will not be experienced.
c. Drain valve shall be installed on the lowest point of mainline installation to facilitate the gravity
draining.
4.18. INSTALLATION OF DRIPLINES
a. Drip line shall be installed as per manufacturer’s recommendations with regards to bank/angle & slope
with regular flushing during the installation to remove debris.
b. Run-length shall not exceed the maximum stated by the manufacturer.
c. An end crimp shall be fitted where necessary to close each end of the line.
d. Drip line shall be held in place by stakes at approximately 1.0meter intervals, generally as per
manufacturer’s instruction.
e. Drip line shall be tested visibly prior to mulching to ensure satisfactory operation.
f. All necessary wall/planter/paving penetration shall be identified and shall be ducted.
g. For the trees and palms, an online emitter, shall be installed as per the approved shop drawing.
h. All the emitters shall be installed on the PE distribution tube with the help of a drip punch. All the
emitters’ locations and quantities are carefully selected based on the actual plant location.
i. Pressure compensating non-leakage dripline shall be provided for areas of ground cover shrubs.
j. The dripline emitters are pressure compensating, on leakage, and self-cleaning in operation spaced at
approximately 30cm intervals at a flow each of approximately 2.3 liters per hour at 1.5 – 2.0 bar pressure.
k. Row spacing will be even and not exceed emitter spacing.
I. Drip lines shall be carefully uncoiled and laid in position without kinking. Any kinked section shall be cut
from the line and subsequently re-joined with a line joiner section.
m. Drip lines shall be snaked as required for maximum coverage without the use of compression fittings.
Sharp bends shall be avoided where there is a likelihood of causing kinks in the line.
n. Drip pipelines shall be installed on the ground as approved detail drawing & approved shop drawing.
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o. Driplines shall be jointed by compression fittings as approved in the material submittal.
p. Drip stakes shall be provided at each point of change in direction of drip line and spacing between drip
stakes shall be not more than 10 meters.
q. Dripline installation includes all air valves and flush end caps for cleaning purposes.
4.19. TIE-IN CONNECTION INTO PRIMARY TSE NETWORK
a. The site-wide TSE network shall provide a minimum flow of 9m 3/hr at 4.0 bar pressure to each one
of the indicated and required connection points with a minimum of 3 No. connection points operating
at any one time.
b. Necessary filtration (automatic self-flushing filtration) and connection point master valve control
shall be provided in a chamber at each point provided.
5. PRE-START SAFETY BRIEFING ARRANGEMENTS
Refer to Risk Assessment on Appendix B.
5.1. PROTECTIVE AND SAFETY EQUIPMENT
All workers Involved shall be equipped with adequate PPE as stated below:
a. Safety Helmet with Company Logo
b. Safety Boots
c. High Visibility Vest
d. Safety Goggles
e. Hand Gloves
f. Coveralls
5.2. INFORMATION TO PERSONNEL
a. Safety Induction
b. Job training
c. Superintendents Notices/Memos
d. Toolbox talks
e. START Card
1. Risk Assessment
Please refer to attached document on Appendix B.
2. Permit and Licensing Requirements
Refer to Appendix C for Permit to Work.
3. Drawings, Diagrams, Maps and Survey Data
Refer to approved Shop Drawings.
5.3. SPECIAL SAFETY REQUIREMENTS FOR METHOD STATEMENT OF IRRIGATION SYSTEM
a. All necessary personal/protective equipment (PPE), as well as harness, be provided.
b. Banksman, wearing distinctive vests, shall be assigned to help operators maneuver their equipment.
c. The equipment operators shall possess the required licenses and certificates.
d. Generated dust shall be controlled by periodic water spraying.
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e. The project safety officer is responsible along with the project zone site engineer for ensuring that all
operations are carried out with due regard to the safety of all project personnel & property.
f. All working activity shall comply with client safety procedure.
g. First aid material.
h. General management of protection/operation hazards are to be observed.
6. ENVIRONMENT AND QUALITY ISSUES
6.1. PRECAUTIONARY MEASURE
All precautionary measures shall be briefed to all workers prior to commencing the activity.
6.2. DISPOSAL REQUIREMENTS
All waste shall be disposed of as per the Construction and Environmental Management Plan, and as per
government-approved disposal areas.
7. INSPECTION, TEST, AND SAMPLING-IRRIGATION SYSTEM METHOD STATEMENT
Request for Inspection and Testing will be submitted prior to and after execution of irrigation works.
8. QUALITY ASSURANCE REQUIREMENTS TABLE
Ensure that work is executed as per approved shop drawing, work method statement for irrigation
system, and records are generated referring to approved ITP.
Best management practices shall also be considered which may be stated by the product manufacturer
or suppliers.
Authority requirements will take precedence over all requirements in case authority approval is to be
secured. For non-authority approval activities, the approved latest project specification will take
precedence.
It is to ensure that regular toolbox training related to work quality is conducted and records are
maintained.
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MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 664 of 864
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NAME:
METHOD STATEMENT FOR
CURTAIN WALL INSTALLATION
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Property of MSS – Approved (Controlled document in Document Repository)
FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 665 of 864
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NAME:
SR. EFFECTIVE REV. MSS MANAGER MSS PROJECT CLIENT
CLIENT QA/QC
NO. DATE NO. QA/QC MANAGER SUPERVISOR
CURTAIN WALL INSTALLATION
The method statement for curtain wall-glazed installation defines the procedure in carrying out the
activity in accordance with the quality, project specifications, health, safety & environment (HSE)
requirements, and approved shop drawings. Site dimensions shall be verified and MEP clearance shall be
obtained before the start of the work on site.
1. SCOPE
2. GENERAL DESCRIPTION
This describes the arrangement and methods for the fabrication and installation of the glazed curtain
walls.
3. DEFINITIONS
Client-xxxxx
Project Management-Construction Management (PM-CM)-xxxxx
Construction Supervision Consultant (CSC)-xxxxx
Main Contractor-xxxx
MEP Contractor-xxxxx
4. REFERENCES
Project Specifications
Approved Shop Drawings and Manufacturer’s Procedure
Approved Material Submittal
5. ABBREVIATION
PM – Project Manager
PE – Project Engineer
QC – Quality Control
HSE – Health, Safety, and Environment
ITP – Inspection Test Plan
IC – Inspection Checklist
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
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DOCUMENT
METHOD STATEMENTS
TITLE:
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MST – Method Statement
RA – Risk Assessment
QCP – Quality Control Procedure
INR – Inspection Request
QA/QC – Quality Assurance/Quality Control
MEP – Mechanical, Electrical, and Plumbing
6. PLANT & EQUIPMENT
The equipment used for the above-mentioned work is:
6.1 SITE SURVEY EQUIPMENT
General Hand Tools
Drill Machines (Light/Heavy Duty)
Drill Bits
Suction Pads
Glass Lifter
‘A’ Frame with Rubber Padding
7. MATERIALS
The materials used for this work are:
Aluminum Profiles: Extruded Aluminium Profiles from Installux. All aluminum profiles are of powder
coating from Jotun
Accessories: Related accessories and gaskets from Installux
Glass: Double Glazed glass
Sealant: as per requirement
Backer Rod: Backer rods as per requirement
Rockwool: 50mm thick Rockwool from
Flashings: 2mm thick aluminum sheet is used as flashing.
Anchorages: Anchorages as per structural calculation
Brackets: Brackets are manufactured according to the structural calculation by fabricating 8mm & 10mm
thick steel sheets.
8. SITE PLANNING & PREPARATION
An initial inspection of the area shall be conducted by a competent surveyor. Its purpose is to
predetermine the control points and benchmarks used in locating the grid lines, which will be the basis of
the layout plan for all elements. The installer will follow the preparation for bracket fixing.
Site survey and marking/lay-out will be done first for anchoring.
Any errors and inconsistencies in benchmark locations, levels, the vertical square of the openings, etc. will
be recorded for necessary rectifications.
Installations in affected areas are set aside till such errors have been corrected.
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FORMATE ID:
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Start the layout and marking of offsets (set-out lines) for elevations and grid lines, the surveyor will use
yellow marking (or any other preferred color) for proper referencing of the curtain wall layout.
The actual dimension of the building’s perimeter and floor-to-floor height shall be verified so that the true
site conditions will be adopted. Any changes and deviations shall be recorded in redline drawings and
reflected in as-built drawings. Data gathered from the verification shall then be forwarded to the
Engineering Department for the design and fabrication correction.
In the event that there are substantial deviations from the pre-set conditions, it shall be reported for
immediate rectification.
9. WORK METHODOLOGY
Make sure that the building is sufficiently readied to receive and enable aluminum works to commence.
The detailed method statement for curtain wall-glazed as mentioned in Section-Installation Method-
Glazed Curtain Wall.
10. ORGANIZATION, RESPONSIBILITIES & SUPERVISION
The site operation activities and control are executed by the following with their corresponding roles and
supervision responsibilities.
The project engineer is responsible for the overall management of work and control of the staff in
executing the work and will perform the following functions.
• To act as the main contact for the main contractor I client /consultant
• To ensure the progress of the project to the agreed program
• To coordinate with the design team
• To make decisions for the day to day project activities
• To control the activities of site engineer and site supervisor
• To ensure the implementation of safety regulations
The foreman will be responsible for:
• To supervise day to day progress of work
• To supervise the quality of work
• To ensure the progress and quality of installation
• To supervise the delivery and routing of materials into the building
• To ensure the implementation of safety regulations
The site surveyor will be responsible for:
• Site survey
• Marking of levels
• Establishing control work points
11. WORKFORCE
PROJECT ENGINEER-
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The overall management of work and control of staff in executing the work is done by the Project
Manager.
Coordinates and supervises the day-to-day work and ensures the progress and quality of work.
SUPERVISOR/FOREMAN-
Coordinate and supervises the installation activities.
ALUMINUM FITTERS-
For fixing curtainwall
GLASS FITTERS-
For the installation of glass
FINISHING WORKERS-
For the application of silicone and for finishing works.
HELPERS-
To help in the installation, unloading, and shifting of materials
12. HEALTH, SAFETY & ENVIRONMENT
HSE CONTRACTOR REQUIREMENTS
The following HSE requirements are applicable to the Method Statement for Curtain Wall
Installation and Risk Assessment.
General Safe Work Practices
Housekeeping Requirements
Emergency Preparedness
Personal Protective Equipment
PROTECTIVE & SAFETY EQUIPMENT
The following HSE requirements applicable to the Method Statement for Curtain Wall and Risk
Assessment
Safety Helmet
Safety Shoes
Safety Glasses
Hand Gloves
13. INFORMATION TO PERSONNEL
Pre-task briefing to be given to the personnel involved in the activity. Supervising staff including Engineers
to be made aware of this Method Statement for Curtain Wall by providing an approved copy.
14. PERMIT REQUIREMENTS
All necessary permits are identified in the safety manuals and will be obtained prior to commencement
of works
15. ENVIRONMENTAL ISSUES
Environmental Impact Assessment
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As shown in the Risk Assessment of the activities, this will have an impact on the environment such
as contamination of air and water and accordingly to be mitigated.
16. OPERATIONAL INSTRUCTION
TECHNICAL DATA & PHYSICAL SAMPLE
Technical data & physical samples required for this work as per the specification had been submitted to
the consultant for approval. Drawings will be made according to the approved profiles. The fabrication
and installation will be done according to the approved profiles and drawings.
• Aluminum profiles & accessories for curtain wall. All the aluminum profiles, accessories, and gaskets
are from Installux.
• Glass
Glazing is from Saint-Gobain (or as per approved material)
• Aluminum finish
All aluminum finishes are of powder coating from Jotun.
• Rockwool insulation:
Azel Rockwool
• Silicone sealant:
• Brackets, anchor bolt, and through bolt:
Brackets & anchor bolts as per structural calculation
17. ALUMINUM SHOP DRAWING
Based on the design calculation detailed shop drawings showing elevations and sectional details will be
prepared. Shop drawings will show details of fabrication and assembly details. Profile details will show the
detailed dimensions and size of sections used and details of material used via the type of material,
supplier, and other relevant details. Shop drawings are prepared in AutoCAD. Shop drawings will be
forwarded for approval with design calculations and consultants’ comments will be reviewed and
resubmitted for final approval.
STRUCTURAL CALCULATION
The project specifications and drawings are carefully reviewed and based on the design wind load and
other structural parameter structural calculations are made and suitable sections for aluminum and
glassworks will be proposed. Brackets, anchors, secondary supports, etc. for curtain walls will be
designed as per specification and the structural calculation and in the line with international and
industry norms/standards.
18. Installation Method-Glazed Curtain Wall
PROTECTION
Before the fabrication process of the aluminum frames starts, a team of workers would apply top-quality
plastic protective tape to all the profiles. The protective tape will ensure that the profiles are not
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damaged or scratched during handling in the factory, transportation to the site, and installation, thus
guaranteeing a final product of high quality.
GLASS PROTECTION:
Polyethylene sheets are used to protect the installed glass. This sheet will be removed only at the
time of glass cleaning prior to site handover.
FABRICATION
All the fabrication works will be carried out at the factory by trained workers, supervised by experienced
technicians, and hence is subject to quality control procedures. Although most of the manufacturing
operations are carried out at the factory under the supervision and control of the quality officer,
nevertheless, a small-equipped workshop could be erected at the site for handling any minor required
adjustments or modifications.
Reinforcement is used for transom and mullion and is installed in required areas as per approved
drawing (Spandrel areas where sunscreen is coming, for example, Resident Housing Spandrel Areas).
FABRICATION OF BRACKETS:
The wall brackets and shoe brackets are designed as per the structural calculation of the curtain wall. An
8 mm thick steel plate is used for the fabrication of brackets. The jig is used for the fabrication of
brackets. The jig is manufactured as per the dimension required for the brackets by using adequate
clearance.
Steel plates are first to cut into required sizes and holes or slots are made as per the requirement. Plates
are clamped to the jigs and tack welding is done within the jig. The bracket is removed from the jig and
full welding is done from outside the jig. Polishing is done to remove spatters and inspection is done.
Galvanizing is done on the fabricated brackets to prevent corrosion.
19. TRANSPORTATION
Once the site conditions enable the start of the installation of the aluminum frames, the units will be
transported to the site and stored in the storage area. All gaskets and accessories are also stored in their
original packing thus preventing any damage or scratches.
Particularly, the EPDM gaskets are stored in their cardboard boxes, not touching the ground, in order to
avoid any damage by moisture or humidity.
20. SITE INSTALLATION
• Prior to installation work, provide the clearances and handover of the areas in writing as required for
installation to proceed. example grid lines, floor level, elevation, and fully erected scaffolding with
floorboard on all working areas.
• All fabricated units are brought and placed at their respective locations manually.
• Site survey and marking/lay-out will be done for the first fix/anchoring.
• Structural shims (plastic/fiber) are used as a standard way to incrementally position and adjust the curtain
wall elements to maintain the level of the brackets.
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• Separators are used between anchorages & adjacent materials to prevent corrosion.
The dielectric material is used as an insulator.
• The wall bracket and shoe bracket will be fixed in the required areas.
• Mullions with brackets are fixed at require areas as per approved drawings are fixed.
• Finished size transoms are fixed to the connection brackets of the mullion.
• Glazing support bracket, insulator, and inner gaskets are installed as per the manufacturer’s
recommendation.
• Glass is installed as per the manufacturer’s recommendation and the outer gasket and pressure plate are
fixed.
• Cover cap is fixed over the pressure plate.
• Installations are carried out in conformity with installation and approved shop drawings as per the system
supplier’s recommendation.
• The glass tempered mark will be installed as per project specification. (Tempered mark logo)
• Glass installation will be done with manual glass lifting or machine glass lifting. In the case of a glass lifting
machine, provide a crane to hook the glass lift during the glass installation work.
• Suction pads and hand gloves are used for glass installation.
Confirmation of Instructions to Operatives Form
The personnel involved in the project confirm the receipt of the Method Statement for Curtain Wall and
had the contents explained and are aware of the HSE requirements.
21. CLEANING & HANDOVER
Protective tape will be removed from the aluminum frame as soon as it is required. The polyethylene
sheet will be removed from the installed glass before cleaning of glass. The final cleaning will be done
prior to progressive joint inspection with the consultant on an area-by-area basis.
Protection of the installed units will be maintained until the acceptance of the handover certificate of the
project.
Distribution of Method Statement for Curtain Wall-Glazed Installation Document
Copies of this MST should be issued to the following for information and action after approval:
Consultant
Main Contractor
Project Manager
Site Engineer
Safety Engineer
Supervisor/Foreman
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22. QUALITY CONTROL/QUALITY ASSURANCE
CONTRACTUAL REQUIREMENTS
Quality assurance requirements as per the contract are covered under the QA program for the timely
inspection and detail ITP-Inspection and Test Plan as per project specification.
23. INSPECTION & TESTING
Quality control is a primary concern in the installation of curtain walls. Quality Control and quality
assurance are strictly monitored during every stage of production from procurement of materials to the
final finished product.
Qualified and experienced inspectors in the factory carry out routine and spot checks to assure a good
quality product. The quality control and assurance procedure are based on the requirements of ISO
9001:2015.
When the production team supervisor considers that the work will be ready to be inspected, he informs
the foreman of the coordination team. The work coordination team foreman then comes to control the
works on-site and reviews all the items mentioned in the Inspection and Test Plan (ITP).
At this point, if the coordination team supervisor discovers any defects, he requests the production team
to correct them. As soon as he ensured that the work is satisfactory, he fills an Inspection Request form
(INR) and gives it to the project team as per standard instruction mentioned on the INR.
The project engineer organizes his team so that the inspection is carried out on the next day and assigns
the foreman to carry out the inspection. If necessary, the project engineer highlights the sensitive points
of the inspection to his foreman before the inspection. In case of necessity, the inspection may be done
the same day.
The project engineer/ foreman checks that all the reference documents are correct and that the quality
criteria are properly defined. He then transmits the original INR to the supervision consultant/ main
contractor for information on the inspection details (works, date, and time of inspections which could be
carried out).
The supervision consultant signs the “receipt”, keeps the original and gives back a copy to the main
contractor’s Quality Department.
The inspection on site is implemented by Construction Department as scheduled in INR with the site
engineer and one supervisor of the supervision consultant/ main contractor if required.
At the end of the inspections, the foreman checks that all the persons concerned have signed the
Inspection Checklist (IC), and prepares the report of inspection contained INR, IC, Delivery Note. Once the
inspection has been completed. The foreman forwards to the Engineer the report to review. The Engineer
consultant keeps the copy and gives back the original with comments if necessary to the main contractor
Quality Department. The project engineer shall ensure that all the comments have been taken into
account.
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24. FOLLOW UP & EVALUATION
Performance of the work is followed up by QA audit and Project Management/Consultant review.
Verification Records
Initial Records Requirements
The following records will be maintained in a file for future checking and submission:
Inspection Request
Material Inspection Request
Mill Certificates
Site Test Reports
Approved Shop Drawing
Redline Drawings
Records During Construction
Inspection Checklist
Completion Certificate Package
The following certificates will be compiled and submitted after work completion:
Site Test Reports
Mill Certificates
As-Built Drawings
Gondola Certificate
Monorail Test Report
Hoisting Machine Certificate
Pull Out Test Report
Water Test Report
Filing Arrangements
All documents will be classified and be kept in files.
Project documentation and records shall be maintained until the completion and handing over of the
project.
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METHOD STATEMENT FOR
CENTRAL BATTERY SYSTEM
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INSTALLATION (CBS)
SR. EFFECTIVE REV. MSS MANAGER MSS PROJECT CLIENT
CLIENT QA/QC
NO. DATE NO. QA/QC MANAGER SUPERVISOR
CENTRAL BATTERY SYSTEM INSTALLATION
1. PURPOSE
The Method Statement For Central Battery System (CBS) Installation describes the sequential approach as
outlined in the project contract requirements which ensures that safety, quality assurance, and quality
control are implemented by the contractor.
2. REFERENCES
This method statement is subject to the requirements as stated in the following regulatory & statutory
documents, applicable standards/specifications/building codes:
Project Specifications
Relevant Sections of IEC/BS
Project approved materials/shop/IFC drawings
Approved Project HSE Plan
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Approved Project Emergency Response Plan
Approved Project Waste Management Plan
3. LOGISTICS
MEP subcontractor will deploy a dedicated team for the required logistics and material movement in–out
of the project.
4. HEALTH & SAFETY HAZARDS
Extreme heat and humidity
Extreme cold, high winds, and dusty condition
Mobile Equipment-Crane, forklift, etc. for material loading/offloading, transfer of materials to work
locations
Temporary electrical supply for lighting, use of power tools, etc.
Improper stacking of materials Internal, external Light fitting, etc.
Manual handling/offloading & installation of internal, external light fitting, etc.
Working on the unsafe scaffold for the installation of internal, external light fitting, etc.
Damaged hand tools-installation of internal, external light fitting, etc.
Uninspected power tool
Unsafe working on ladders
Poor housekeeping & waste management
5. PERMITS AND CERTIFICATES
Hot work permit (cutting/grinding)
Lifting plan
Confined space
Lockout/tag-out permit
Working at heights/working on scaffolding
MEWP – Third-party certification for the operator and the equipment. Competence certification for
workers.
6. DEFINITIONS
MST–Method Statement
QCP–Quality Control Procedures
ITP–Inspection and Test Plan
ITA–Independent Testing Agency
CBS-Central Battery System
7. RESPONSIBILITIES
PROJECT MANAGER
The Project Manager shall be responsible for overall project planning, procurement, technical
submissions, and drawing submissions.
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The Project Manager shall coordinate activities within the site team and with the management for the
timely completion of activity in accordance with contract requirements.
CONSTRUCTION MANAGER
The Construction Manager is responsible for the work execution in compliance with the approved method
statement, HSE Risk Assessment, project specification, issued for construction drawings, sections, and
details.
SITE ENGINEER
The Site Engineer is responsible to carry out the work as per approved shop drawings and method
statements. He is also responsible to ensure adequate tool kits required for the works are in place prior to
the starting of work. The Site Engineer reports to the Construction Manager.
The Site Engineer is responsible to ensure work has been done as per the specification and drawings;
inspections are carried out based on approved Method Statement for Central Battery System (CBS)
Installation, ITP, and quality control procedures and coordinate with QA/QC department for inspections.
The Site Engineer is responsible to ensure that all safety precautions are ensured in place and that all
personal on-site are using the required personal protective equipment like helmets, gloves, shoes, and
reflective jackets. The Site Engineer in coordination with safety officers will ensure all relevant
permissions are taken prior to commencement of works.
The Site Engineers shall ensure that the works are supervised by a competent supervisor till the
completion of the task.
QA/QC DEPARTMENT
The QA/QC department will be responsible for overseeing the quality requirements and quality control
measures for the project in coordination with the project engineer and construction manager.
SAFETY ENGINEER
The HSE Officer will be responsible for the safety, health, and environmental aspects on site as per the
project safety and environment requirements/safety standards in coordination with the project engineer
and construction manager.
Method to be Employed-Central Battery System (CBS) Installation
SITE PLANNING & PREPARATION
Before installation takes place, the following pre-installation task is essential:
Identify and ensure that the pertinent document like the approval for Shop Drawings, MEP coordination
drawing, CBS installation details, load schedule approved life and safety drawing shall be available at the
site.
Permits shall be applied prior to commencement of works.
Please ensure to obtain the necessary PTW (Permit To Work), prior to allowing to work. Frequently
training should be conducted by the site supervisor/foreman. A daily safety briefing should be conducted.
Applicable permits shall be applied prior to the commencement of works.
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NAME:
The start of CBS and accessories installation shall be done in accordance with approved shop drawings
and properly coordinated with site engineers for the exact locations and levels. Marking on-site to be
carried out prior to commencement of installation works.
Conduct site safety briefing prior to commencement of work.
Identify and obtain appropriate installation tools and equipment.
Determine the staffing required and assign tasks to team members.
Perform lockout/tag-out procedures (where applicable) during installations.
8. HANDLING OF MATERIALS
Upon receiving the materials, all must be inspected and ensured that there are no manufacturing defects
and delivery damages. Upon receiving the materials, all must be inspected and ensured that there are no
manufacturing defects and delivery damages.
Arrange internal and external inspection to ensure conformity of the delivered materials against approved
material submittal.
All materials shall be stored and handled as per the manufacturer’s written recommendations. It is
important to note that in the case of controllers & batteries proper handling care and humidity conditions
shall be taken care of. The maximum operating temperature and humidity conditions shall be observed at
the place of material storage.
During shifting to the installation location, as possible keep the packaging/pallet intact and lift using
proper lifting equipment or manually with an adequate number of people. Handle with care to avoid
damage to internal components and the enclosures. (Follow handling guidelines recommended by the
manufacturer).
Store the materials in the manufacturer’s original packaging in the manner that labels are so arranged for
easy identification, to avoid mismatches of loose components.
Only required materials to be shifted to site and store temporarily and ensure extra materials are not
dumped on-site and congest the working area.
Once work is completed extra materials and tools are to be returned back to stores.
9. INSTALLATION OF CENTRAL BATTERY PANEL
PRE-INSTALLATION WORK
All workers to attend safety induction training on the safe installation methods by the safety
department.
Ensure all central battery system materials received are inspected by the consultant and found
acceptable as per approved materials submittal.
Ensure that all related materials are of approved make and are available before carrying out any work.
Ensure all drawings are the latest revision, approved for construction issue, and are fully coordinated
with all other services and installations
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 679 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
A safe start procedure shall be prepared before commencing the work. Permit to work system to be
followed for the installation of central battery panel.
The area to be cordoned off and all other works should be kept at a safe distance. Suitable firefighting
equipment’s to be provided at the working area.
Prior to commencing any works, a risk assessment must be conducted, taking into account all possible
risks and the appropriate precautions put in place, i.e. fire extinguishers, fire blankets, safety harnesses,
etc. Refer to the risk assessment/risk management section of this method statement for central battery
system installation.
All works shall be undertaken in a neat and workmanlike manner to ensure a quality installation.
Permit to work system to be followed if required proper PPE to be worn by all operatives always on site.
INSTALLATION
Ensure the installation central battery system and other accessories are as per the approved method
statement for the central battery system, material, and shop drawings and coordinated with other
services.
Ensure prior to installation all CBS’s are approved by consultant and it is free of damages.
The location should be marked for the installation of the CBS panel as per approved shop drawings.
Ensure the installation of the central battery system panel/cabinet is as per approved shop drawings and
coordinated with other services. Ensure the installation of the CBS panel/cabinet is as per manufacturer
recommendation and the procedures to be followed.
Verify the CBS panels are tagged correctly before they are prepared for site installation as per project
specification.
Drill holes on the concrete wall and install the raw bolts. The size of raw bolts should depend upon the
size of the CBS and should be as approved detail drawing.
Installed CBS panels and securely attached to the walls with expansion anchors. Check the horizontal
and vertical alignment by a spirit level.
Assemble the batteries adopting the following procedures:
Cells/Batteries should be connected ensuring that the positive terminal (+ or RED) of one cell/battery is
connected to the negative terminal (- or BLACK/BLUE) of the adjacent cell/battery. Positive and negative
conductors should not pass through the same holes. After connecting the battery ensure that each link
surface and battery terminal is covered with an even coating of petroleum jelly to ensure good electrical
connection and protection against corrosion of terminals during service life.
When the battery has been fully assembled, check that all nuts and bolts are tightened as per the
battery manufacturer’s instruction and that all nuts, bolts, and pillars of the cell have been coated with
petroleum jelly.
Make a visual check from the start to the finish of the battery to ensure that the cells/batteries are
connected as described above.
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Page 680 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
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Remove battery fuses, charger fuses, and ensure that MCB and external remote isolator are OFF. Check
all inverter modules MCB’s (Miniature Circuit Breaker) are OFF and remove all inverter module fused
(they are small cartridge types and should be kept in a safe place).
Connect the battery to the battery cable with care positive lead to the end marked + or RED end of the
battery, negative Lead to the end market, or blue/black end of the battery.
Check that all the required wires/cables are completed and ready for final termination/connections.
Carry out insulation resistance test and continuity test for the wires/cable prior to final termination
works.
Bring the incoming mains cables and load output cables in the cable gland holes provided in the charger
compartment and connect as detailed, referring to the wiring diagram supplied. When using gland
plates for cable termination, remove the gland plate before drilling.
Connect the live lead to the terminal marked L or in the case of 3 phase input L1, L2, and L3. Connect the
neutral lead to terminal marked N. Connect the earth lead to the earth stud provided.
Maintained system only – should a remote maintained circuit switch be required, remove the factory
fitted link between the terminals marked RSL or LK2 and replace it with a remote switch.
The remote monitor relays should be required to remove the factory-fitted link between terminals LK1
and connect the remote monitor contact normally open series loop between the terminals.
Connect the load circuit to the output terminals, fused or MB’s. Observe the correct polarity. If the
system is complete with an integral sub-circuit monitor, fire alarm relay terminals for the connection of
a remote alarm unit, or terminals for remote indication of system fault via volt free change over contact
these should be connected as required.
Ensure that the inhibit switch located inside the cubicles is in the inhibit position. Install the central PC
and associated devices in the allocated control room as shown in the approved shop drawings.
Check the completed installation against the checklist for the installation inspection of the emergency
lighting central battery system that is attached in the approved method statement.
Once the completed installation is confirmed to have satisfactorily complied with the installation
inspection checklist mentioned above a request for installation may then be initiated in order to obtain
the required consultant’s approval for the completed installation of the emergency lighting central
battery system.
10.TRAINING
All required training for stipulated installation activities is provided to all technical staff for ensuring
quality workmanship.
11.WORKING HOURS
Site operational time shall be followed as per project progress requirements, all relevant local authority
schedule of holidays to be observed.
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12.HOUSEKEEPING
Working areas will be kept clean by disposing of the waste materials at the designated areas. At the end
of the days’ work, the installation supervisor will ensure that the debris is disposed of during the course of
the activity on regular basis. Dust created by work e.g. drilling, of the slab, grinding, and polishing.
The area must be isolated/protected by a green net and required additional PPE for the operatives. Any
materials stacked in the site shall neither obstruct the emergency evacuation route.
13.MANPOWER
Subject to main contractors’ programmer and scope/area available for MEP activities, but not limited to
below:
Electrical Engineer
QA/QC Engineer
Safety Engineer
Riggers
Equipment Operators
Foreman
Charge hands
Electricians
Assistant Electricians
Scaffold erectors
Welder (for support/bracket fabrication)
Helpers
14.MATERIAL
CBS panel and accessories.
Wires and cable (includes accessories such as lugs, ferrule, cable ties, etc.)
Bolt, nuts, and washers
Raw plugs and screws
Anchor bolts/hammer set anchor
Strut channels
15.PERSONAL PROTECTIVE EQUIPMENT REQUIREMENT
Safety helmet
Safety goggles
Safety boots
High visibility vest
Hand gloves
Earplugs
Respiratory protection
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Full body harness
16.TOOLS & EQUIPMENT
The following equipment and tools shall be used for the works:
Standard Electrician Tools and Toolbox
Electric Drill and set of bits
Cutting Tools (e.g. Jigsaw, Grinder)
Set of wrenches (fix or adjustable)
Set of files
Hammer
Plumb bob/Spirit Level
Air Blower/Vacuum Cleaner
Measuring tape
Hand gloves
Lifting Equipment (e.g. mobile crane, forklift for loading and unloading during delivery/shifting)
Appropriate Safety equipment (PPE)
Ladders (Appropriate Type)
Scaffolding (and fittings/accessories)
Notes:
1. Third-party certification (Competence Certificates) for workers, operators, equipment valid registration,
insurance and fitness certificates, operator daily inspection checklist should be available for Safety Officer
validation before commencing the works.
16. QA/QC REQUIREMENTS FOR METHOD STATEMENT FOR (CBS) INSTALLATION
Follow approved MST, ITP, QCP, HSE Plan, and Material Approval & Checklist.
17. ATTACHMENTS
Risk Assessment
Inspection & Test Plan
Quality Control Checklists
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Page 684 of 864
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METHOD STATEMENT FOR
BUS DUCT INSTALLATION
SR. EFFECTIVE REV. MSS MANAGER MSS PROJECT CLIENT
CLIENT QA/QC
NO. DATE NO. QA/QC MANAGER SUPERVISOR
BUS DUCT INSTALLATION
1. PURPOSE
This method statement for bus duct (fire rated) describes the installation activity to ensure that it
complies with the project requirements, HSE, specifications, and standards.
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2. SCOPE
The scope of this method statement covers the installation of the fire-rated bus duct which gives
guidelines for the job execution in compliance with the requirement of the specification and as approved
by the concerned authority.
3. DEFINITIONS
Client-xxxxx
Project Management-Construction Management (PM-CM)-xxxxx
Construction Supervision Consultant (CSC)-xxxxx
Main Contractor-xxxx
MEP Contractor-xxxxx
Manufacturer- EAE Elektrik
4. REFERENCES
Project Specifications-(Enclosed Busway Assemblies)
Approved Shop Drawings and Manufacturer’s Procedure
Approved Material Submittal
5. ABBREVIATION
PM – Project Manager
PE – Project Engineer
QC – Quality Control
HSE – Health, Safety, and Environment
ITP – Inspection & Test Plan
MST – Method Statement
PPE – Personal Protective Equipment
MSDS – Material safety data sheets
RA – Risk Assessment
QCP – Quality Control Procedure
INR – Inspection Request
QA/QC – Quality Assurance/Quality Control
6. RESPONSIBILITIES IN METHOD STATEMENT FOR BUS DUCT (FIRE RATED) INSTALLATION
5.1. GENERAL
The Project Manager will be responsible to manage, execute complete and handover the MEP
construction activities within approved budgets and resources in compliance with Project Requirements
as specified in Project Specifications. He will be overall in charge of implementing the Method Statement
for Bus Duct (Fire Rated) Installation in accordance with QA/QC and HSE requirements.
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CONTRACTOR
NAME:
The Construction Manager will be responsible for managing MEP construction activities and will lead
and communicate with site supervision, subcontractors, and vendors to assist them in working to the
project schedule by conforming to QA/QC and HSE requirements at the site.
The HSE Manager will be responsible for plan, coordinate, and implement issues and directives within
the organization. He ensures safe environmental working conditions for all MEP employees.
The QA/QC Manager Manager will be responsible for supporting the project MEP team in implementing
and maintaining Quality Management System for the project through PQP, ITP, Method Statement for
Bus Duct (Fire Rated) Installation, and Procedures in compliance with Project specifications, Codes, and
Standards.
The Site Engineer will be responsible for carrying out all construction-related activities as per contract
specifications, drawings/documents, codes, and standards and In-line with HSE and QA/QC
requirements together with Project Engineer for fire-rated duct bus works.
The QA/QC Engineer will be responsible for conducting inspections as per PQP.
HSE Officer will ensure enforcement of safety procedures in accordance with the approved HSE Plan. He
will be closely monitoring the site engineer’s strict implementation of the Method Statement for Bus
Duct (Fire-Rated) Installation and Risk Assessment, the use of proper tools and equipment to maintain
safety, certifications of equipment and their adherence to safety regulations, reporting of any unsafe
work or stopping work that does not comply with HSE procedures.
Electrician/other tradesmen will be responsible for assisting his superiors during all installation work-
related activities. Work shall be in line with HSE and QA/QC requirements. Supervise closely, the
activities designated to them and ensure that all instructions and safety procedures are followed and
strictly adhered to.
Store in-charge receives and inspects all incoming materials and reconciles with documents; processes
and distributes documentation; reports, documents, and tracks damages and discrepancies.
7. LIST OF CONTRACTORS/SUBCONTRACTORS
Main Contractor-xxxx
Sub- Contractor for MEP-xxxx
Supplier Name-xxxx
Material Brand-EAE Electrik, Turkey
8. HANDLING, STORAGE, AND TRANSPORTATION
Upon receiving the material, it must be inspected and ensured that they are free from any manufacturer
defects.
The material shall be handled with care and shall be stored at the designated area as per the
manufacturer’s recommendation prior to installation.
Any discrepancies, damages, etc., shall be notified and reported for further action.
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The busbar is protected from minor water ingress by means of an overall outer polythene wrap and
individual polythene stretch wrap around the ends of each busbar.
The material will be delivered at the site in undamaged condition in the manufacturer’s packaging with
identifying labels intact and legible.
Each shipment must be blocked and securely fastened to avoid damages during transportation.
Unloading at the site must be controlled by site management following the manufacturer’s instructions.
Manufacturer recommendations shall be followed strictly while handling the material during installation
activity.
Lay down area must be arranged for offloading the material prior to transport to the site.
Ensure that the storage area is at a minimum height of 1 ft from the ground level.
Ensure that the proposed storage area for the material is clean.
A separate area in the storage zone must be marked for different materials.
Ensure that the material is stored in a shaded area to protect it from exposure to direct sunlight.
If the busbar is not to be installed immediately upon delivery, it should be stored in a clean and dry area
to prevent condensation. Do not allow the busbar to contact with corrosive fumes, liquids, and other
foreign matters.
9. MATERIAL INSPECTION
For material to be inspected after receiving at the site (as per approved material submittal) the following
points are to be followed:
Each material item shall be allotted a distinct and separate reference number and mentioned on the
material requisition. Make sure that material is approved/examined by the consultant, QAQC, and
associated documents/test certificates are approved.
The store in-charge shall ensure that all approved supplies be delivered to the site as per the approved
material submittal with the manufacturer’s seals, labels, or other proof of origin. These labels and seals
shall not be removed until the material is required for use and shall be retained for inspection by the
consultant and QA/QC.
Store in-charge shall initiate material inspection for all incoming material to QA/QC and the material shall
be inspected against reference documents and as per approved material submittal. Moreover, the
physical condition of the material shall be checked. Afterward, an INR shall be raised by QA/QC to the
consultant and inspection will be carried out by the consultant.
Materials, which do not conform to the given specification/approved material submittal, shall be rejected.
Any discrepancy or damages will be notified and reported for further action.
For any material inspection (especially pipes, fittings, other accessories), the items shall be segregated as
per their types/sizes and placed items separately in racks or on different pallets.
Each rack/pallet shall have an identification posted on a laminated paper with the description of the items
are clearly written on it.
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There shall be appropriate spaces between the pallets so that the engineer/inspector can freely go
around them and inspect the materials thoroughly.
Staking the materials all over each other & in one corner is strictly not allowed.
10.RESOURCES
TOOLS AND EQUIPMENT
The job will be carried out by manual means. The following are the types of Tools identified for works:
Fork Lift for transporting Busbar
Chain Block pulley (suitable capacity)
Portable Hand Tool
Measuring Tape
Marker Tape
Spirit Level (1.5m to 2m long)
Drilling Machine
Torque Wrench tools
Level Threads
Hammer
Multimeter
Standard Electrical tool kits
1000V Megger
Simple Electrical Tools (plier, screwdriver set and etc.)
Ladder
Note:
All testing equipment and measuring tools to be used shall have valid calibration certificates prior to
usage.
Equipment and machines shall be 3rd party verified with valid certificates
Operator’s competency certificates shall be checked and maintained as quality and HSE records.
The contractor’s HSE inspection for all light and heavy equipment prior to site acceptance shall be
carried out.
HSE inspection sticker shall be posted on the windshield to indicate that the equipment passed
inspection.
MATERIALS
Material includes but is not limited to the following:
KXC series Copper Bus Bar
Epoxy paint – RAL 7038 (Light Grey)
Class B insulation and tinplated joints
IP55 protection housing for vertical
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IP65 protection housing for horizontal
11.LIST OF MANPOWER
Project Manager
Construction Engineer
Senior Engineer
Site Engineer
Supervisor/ Foreman
QA/QC Manager
Electrician
Helpers/Laborers
Safety Officer
First Aider
QC Engineer
12.METHODOLOGY-BUS DUCT (FIRE RATED) INSTALLATION
PREPARATION FOR INSTALLATION
The start of the busbars installation shall be done in accordance with approved shop drawings and
properly coordinated with site engineers for the exact locations and levels. The. mark on-site to be
carried out prior to commencement of installation works.
Prior to the commencement of the works, inspect the areas for safe access and confirm the same are in
suitable condition for the works.
All materials and documentation relevant to this particular works shall be checked by the project
Engineer to confirm adequacy and compliance with the requirements prior to the commencement of
works.
Only approved materials shall be used for the site works. Material inspection approval shall be checked
and verified by the Project Engineer.
The Project Engineer or Site Engineer should check the approved isometric drawings of busbar layout
and ensure that all sections of the busbars are received at the site.
During shifting to the installation location, lift the busbar and its associated fittings using proper lifting
equipment or manually with an adequate number of people. Never drag the busbar across the ground,
handle with care to avoid damage to internal components and enclosure.
Prior to the start of the installation works, the team shall coordinate with the builder’s work activities at
the site to ensure the proper work installation.
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Prior to installation, ensure that approved shop drawings for construction details of bus duct
arrangement and bus duct routing are available as approved by the supervision consultant. This drawing
should be followed carefully to ensure a proper busbar system.
All involved personals will wear appropriate protection at all times during the entire period of
unloading/ shifting.
Hazard analysis and risk assessment shall be explained to all personnel involved in the installation of the
busbar and its accessories.
After satisfactory completion of the above steps, works shall commence in the respective areas.
Works shall be carried out at site under strict supervision and guidance of the supervisors/engineers.
INSTALLATION/WORK SEQUENCE
Installation of busbar starts from the transformer to MV Panel. During the installation, a chain block (1-2
tons) will be used to lift the busbar and its components to their proper position as per the approved
drawing. During the installation process workers involved wears appropriate safety protections.
Distribute pieces of the busbar and its associated fittings to each level as per the approved drawing
details of bus duct arrangements. In shifting the materials to each level tower crane/forklift will be used
or manually with an adequate number of people. All involved personnel must wear appropriate
personnel protection during the entire period.
Install horizontal busbars & vertical busbar riser including its supports in accordance with the approved
specification, manufacturer’s recommendation & approved shop drawing.
HORIZONTAL MOUNTING SUPPORT
Use approved channel/hanger flat & down the rod as per manufacturer’s recommendation.
Busbars are installed by tightening the “one bolt joint”. Belleville spring washers on both ends of the
bolt retain the original contact pressure, ensuring a more secure, reliable, and maintenance-free joint.
Once the busbar is aligned and jointed properly, the bolt is tightened to 83Nm (60 lb-ft) using the torque
spanner.
During the installation maintain good alignment of the drop rods along the busbar run; do not support
the busbar at the joints. After the busbar is secured in the hangers, adjust the hangers on the rod for the
correct elevation.
Use min 10mm galvanized steel bolt to fix busbar to supports with required nut and washer.
The joint shall be done as per the manufacturer’s recommendations; this is to avoid any ingress of
moisture into the bus duct system.
Prior to joining, both sections of the bus duct to be joined undergo continuity & insulation resistance
tests and record the results in the approved format. Joints shall be made by simply sliding together the
bus duct unit, and tightening the clamping bolts progressively to the specific torque (83Nm). Ensure that
all joint contact surfaces are free of contamination and dirt.
Install expansion joint wherever required in accordance with contract documents, approved shop
drawing & manufacturer’s recommendations as well as on every building expansion joint.
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13.PANEL CONNECTION UNITS
Supplied with suitable flange as standard (See fig below).
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BUSBAR FLANGES CONNECTIONS
After the erection, use vinyl or corrugated cardboard or polythene sheets to cover the power busbar
system, protection for concrete, plaster, and water damage, etc.
14.TRANSFORMER TERMINAL CONNECTION
Make sure the rigid busbar is connected properly. On the top of the LV cable box, the transformer
connection unit is to be installed, and then flexibles are used to connect the connection unit to
transformer terminals.
Joints shall be made by simply sliding together the unit, and tightening the clamping bolts progressively to
the specific torque (83Nm). Ensure that all joint contact surfaces are free of contamination and dirt.
Any missing tools or equipment shall be provided for perfect installation.
Upon completion of installation manufacturers or dealers, engineers will inspect and certify the
installation.
Ensure a danger notice is fitted to all access panels where a voltage exceeding 200V and the power busbar
system is protected until the building is clean, and the system is ready to be energized.
When installing a busbar section with a fire barrier ensure that the fire barrier protrudes from both sides
of the wall. Final sealing between fire barrier and wall to be completed.
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15.CONTINUITY TESTING OF BUS BAR
Prior to installation of power busbar system and before electrical circuitry has been energized,
demonstrate product capability and compliance with requirements.
Perform continuity test to both sections of bus duct to be joined and to be recorded to ensure proper
connections. If satisfactory readings cannot be achieved, remove and replace mal-functioning busbars
with new units and retest.
Measure resistance between phases, and earth using megger. (The mega ohm readings should not be less
than the value recommended by the manufacturer.)
Upon installation, measure the resistance of each major branch. In case of low readings, re-tighten all
joint bolts in the busbar section being tested using a torque wrench. If satisfactory readings cannot be
achieved, remove and replace mal-functioning busbars with new sets and retest.
16.INSPECTION AND TEST PLAN
The engineer should verify that the supervisor/foreman with construction responsibilities for installation
is familiar with this method statement and is issued with copies of the inspection checklists and test plans.
The engineer should satisfy the procedures provided by QA/QC inspections to ensure the as-installed
condition of the Busbars installation meets the specified engineering requirements and approved
drawings.
As part of the assessment, the QA/QC Inspection Procedures must ensure quantitative or qualitative
acceptance criteria for determining the prescribed activities have been accomplished satisfactorily.
The QC inspection personnel in coordination with the Site Engineer and Supervisor should verify that the
quality of the related Busbars installation activities is within the prescribed criteria.
The Site Engineer should verify any as-built record of Busbars installation. Confirm that the information
meets the project requirements.
Quality Control Engineer along with Project Engineer and Site Supervisor will monitor that all components
are installed as per contract specifications and approved submittals.
Inspection Request (INR) shall be submitted by QA/QC Engineer for verification and inspections along with
the manufacturer Engineer Site inspection report with the stamp.
Readable stamped approved drawing to be available during installation and inspection.
All the equipment engaged for testing shall have a valid calibration and a certificate should be furnished.
17.HEALTH AND SAFETY ANALYSIS
RISK ASSESSMENT
Refer to Risk Assessment/Job Hazard analysis on Appendix A
ENVIRONMENTAL IMPACT ASSESSMENT
This activity does not have a feasible impact on the environment.
Generated waste will be managed by an approved waste management company.
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18.WELFARE FACILITIES
All welfare facilities which include: Mess Hall, Toilet Facilities, First-aid room, Clinic, etc. shall be provided
and properly maintained, cleaned, and neat.
Periodic Inspection of these welfare facilities should be done to make sure they are up to required
standards.
All workers involved shall be equipped with adequate PPE as state below:
Safety Helmet with Company Logo.
Safety Boots, Safety Goggles, Hand Gloves.
High Visibility Vest.
Twin-Tail Harness, Max 1 m long (when working on height) All special PPE (Harness) are considered as last
resort when we cannot engineer, administratively eliminate, or guard against hazards.
19.INFORMATION TO PERSONNEL
Safety Induction
Job Training
Superintendents
Notices/Memos
Toolbox Talks
Briefings before starting work
20.HOUSEKEEPING
Working areas will be kept clean by disposing of the water materials at the designated areas. At the end
of the days’ work, the installation supervisor will ensure that the debris is disposed of.
21.QUALITY ASSURANCE AND QUALITY CONTROL
Quality Assurance and Quality Control of Method Statement for Bus Duct (Fire Rated) Installation
The contractor shall provide the required documents for consultant approval prior to initiating the
execution of this activity as per the project specification.
The quality control requirement shall include related QCP’s, ITP’s and other related documents as
applicable.
Applicable codes and standards for materials
Project Specifications
Quality Assurance Process
The contractor shall notify the Engineer 24 hours in advance prior to starting of activity and comments
from the Site Instruction will comply with the satisfaction of the consultant.
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Follow up and Evaluation
The contractor shall consult the public utility authorities not less than one month before it is proposed to
commence work to ascertain whether any underground installations will be affected by the proposed
work, in which event the contractor shall make all necessary arrangements with the public utility
authorities to safeguard the installation.
Follow up on quality performance shall be carried out through an in-house monitoring system such as
progress reporting to the planning department, daily, weekly, and monthly reports generated by the
planning department to closely monitor site performance in general and reflect on the quality
performance in specific
All the above shall be in close coordination with the quality department to monitor any deviations from
the normal quality requirement and induce corrective actions whenever required to eliminate non-
conformance or quality deviations
All remedial actions to be taken, if any, shall take into account the official schedule which is used as
guidelines for performance and most importantly under the close supervision of the quality control
department.
22.RECORDS
Checklist (CL)
Inspection Request (INR)
Inspection and Test Record (ITR)
23.LIST OF APPENDICES
Appendix A: Risk Assessment
Appendix B: Inspection Test Plan
Appendix C: Checklist for installation of Fire Rated Bus Duct
Appendix D: Manufacturer’s Installation Procedure
Appendix E: Approved Material Submittal
Appendix F: Reference Drawings
Appendix G: Organization Chart
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METHOD STATEMENT FOR
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CCTV INSTALLATION
SR. EFFECTIVE REV. MSS MANAGER MSS PROJECT CLIENT
CLIENT QA/QC
NO. DATE NO. QA/QC MANAGER SUPERVISOR
CCTV INSTALLATION
1. PURPOSE
The Method Statement for CCTV (Closed Circuit Television System) defines the documentation and
responsibilities for controlling the installation of CCTV systems for the project as specified in project
specifications and instructions. The method statement ensures that the specified material is installed and
agreed procedures are implemented during the execution of work
2. SCOPE
The scope of this method statement encompasses the installation of CCTV to give guidelines and ensure
that the job execution complies with the requirements of the specification and requirements as approved
by the concerned authority up to the highest quality level of the project specification.
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3. REFERENCES
Project Specifications (Electrical Installation)
Approved Shop Drawings
IFC Drawings
Approved Material Submittal
CCTV-Closed Circuit Television Manufacturer’s Schematic Drawings/Catalogs
4. ABBREVIATIONS
QC – Quality Control
HSE – Health, Safety, and Environment
ITP – Inspection & Test Plan
MST – Method Statement
CCTV – Closed Circuit Television System
MSDS – Material Safety Data Sheets
RSK – Risk Assessment
QCP – Quality Control Procedure
INR – Inspection Request
PQP – Project Quality Plan
5. RESPONSIBILITIES
GENERAL
The Project Manager (MEP) will be responsible to manage, execute, complete and handover the
construction activities within approved budgets and resources in compliance with requirements as
specified in project specifications. He will be overall in charge of implementing the Method Statement
for CCTV (Closed Circuit Television System) Installation in accordance with QA/QC and HSE
requirements.
The Construction Manager will be responsible for managing construction activities, communicate with
the site supervisor, and assist the subcontractors and vendors in working to the project schedule.
HSE Manager will be responsible for plan, coordinate, and implement issues and directives within the
organization. He ensures safe environmental working conditions for all staff and workers.
QA/QC Manager will be responsible for supporting the project team in implementing and maintaining
Quality Management System for the project through PQP, ITP, Method Statement for CCTV, and
Procedures in compliance with Project specifications, Codes, and Standards.
HSE Officer will ensure enforcement of safety procedures in accordance with the approved HSE Plan.
Will be closely monitoring the site engineer’s strict implementation of the Method Statement for CCTV
(Closed Circuit Television System) Installation and Risk Assessment.
Maintain the safe use of proper tools and equipment.
Report any unsafe work or stopping work that does not comply with HSE procedures.
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The Site Engineer will be responsible for carrying out all construction-related activities with compliance
to HSE and QAQC requirements as per contract specifications, drawings/documents, codes, and
standards.
QA/QC Engineer will be responsible for conducting inspections as per PQP.
Supervisor/Foreman will be responsible for coordinating all works and workers related to job.
Electrician / other tradesmen will be responsible in assisting his superiors during all installation of the
electrical work.
Store In-charge receives and inspects all incoming materials and reconciles with documents; processes
and distributes documentation; reports, documents, and tracks damages and discrepancies.
The security guard will be clearly visible, vigilant, respond quickly and correctly during the crisis,
observing, reporting, checking, monitor, maintain order among workers, and offer safety warnings and
tips.
6. HANDLING, STORAGE AND TRANSPORTATION
All materials shall be handled/transported/stored should comply with project specifications and
manufacturer recommendation.
The material will be delivered at the site in undamaged condition, in the manufacturer’s packaging, with
identifying labels intact and legible.
Upon receiving the material, they must be inspected and ensured that they are free from any
manufacturer defects.
The material shall be handled with care and shall be stored at designated areas prior to installation.
Any discrepancies, damages etc. shall be notified and reported for future action.
Camera cable shall be with the factory packing on the flat surface.
The cabinet must be stored on a smooth and leveled surface.
CCTV equipment to be stored as per manufacturer’s recommendation.
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Each shipment must be blocked and securely fastened to avoid damages during transportation.
Unloading at the site must be controlled by site management following the manufacturer’s instructions.
Manufacturer recommendation shall be followed strictly while handling the material during installation
activity.
Lay down area has to be arranged for offloading the material prior to transport to the site.
Ensure that the storage area is at a minimum height of 1 fit from the ground level.
Ensure that the proposed storage area for the material is cleaned.
A separate area in the storage zone must be marked for different materials.
Ensure that the material is stored in shaded area to protect it from exposure to direct sunlight.
All the materials have to be offloaded from vehicles using forklifts and slings. Ensure when transporting
load for fork should not raise more than 8 inches from the ground and the load should be titled back,
never carry loose or poorly stacked loads. Never put hands or legs in the lifting.
Whenever heavy or bulky material is to be moved, the material handling needs will be evaluated in terms
of weight, size, distance, and path of movement.
7. MATERIAL INSPECTION
For materials to be inspected after receiving at site as per approved material submittal.
The following points are to be followed:
Each material item shall be allotted a distinct and separate reference number and mentioned on the
material requisition. Make sure that material is approved/examined by the Consultant and QAQC and
associated documents/test certificates are approved.
The Store In-charge shall ensure that all approved supplies be delivered to the site as per the approved
material submittal; with the manufacturer’s seals, labels, or other proof of origin intact. These labels and
seals shall not be removed until the material is required for use and shall be retained for inspection by the
Consultant and QAQC.
Store In-charge shall initiate material inspection for all incoming material to QA/QC and the material shall
be inspected against reference documents and as per approved material submittal. Moreover, the
physical condition of the material shall be checked. Afterward, an INR shall be raised by QA/QC to the
Consultant and inspection will be carried out by the Consultant.
Materials that do not conform to the given specification/approved material submittal shall be rejected.
Any discrepancy or damages will be notified and reported for further action.
For any materials inspection (especially pipes, fittings, other accessories), the items shall be segregated as
per their type/sizes and placed items separately in racks or on different pallets.
Each rack/pallet shall have an identification posted on a laminated paper with the description of the items
clearly written on it.
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There shall be appropriate spaces between the pallets so that the engineer/inspector can freely go
around them and inspect the materials thoroughly.
Staking the materials all over each other & in one corner is strictly not allowed.
8. RESOURCES
TOOLS AND EQUIPMENT
The job will be carried out by manual means. The following are the types of tools identified
for works:
1. Standard electrical and mechanical tool kits
2. Qualified fluid tester (signal analyzer)
3. Drill machine
4. Crimping tool with crimping bits for all required sizes.
5. Network MAK Address Scanner software (by axis )
6. Multi Tester or DMM
7. Digital Multimeter
8. Measuring tape
9. Electrical hand tools
10. Marker pen
11. Electrical tools consist of the cutter, pliers, stripper with dipped grip handle, long nose, screwdrivers,
hammer, continuity tester, crimper, knife, etc.
Note:
All testing equipment and measuring tools to be used shall have a valid calibration certificate prior to
usage.
All lifting equipment and machines shall be 3rd party certified with valid certificates.
9. MATERIALS
Materials included but not limited to the following as per approved material submittal:
Approved Cameras
VMS (CP MER Connected Camera)
Network Video Recorder for FPS and SWPS
Monitor and workstation (CP MER connected Camera)
The material shall be used as per approved material submittal which shall conform to the project
specification and authorities regulations (where required).
10.LIST OF MANPOWER
Construction Manager
Site Engineer
QA/QC Engineer
HSE Officer
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Supervisor
Foreman
Electrician/Installers
ELV Technician
Surveyor
Helpers
Trailer Driver
Mobile Crane / Crane Operator
Forklift Operator
Riggers
11.METHODOLOGY
INSTALLATION OF CCTV (CLOSED CIRCUIT TELEVISION SYSTEM)
PRE-REQUISITES
Location/area shall be ready for site installation. Prior to the installation the area where the item to be
installed shall be inspected to ensure architectural work and finishing are complete. The area must be
free from dust.
All personnel to have read and understand the Method Statement for CCTV (Closed Circuit Television
System) installation and risk assessments.
Site supervisor/foreman need to conduct toolbox talks and require explaining the related work and the
cable routing location etc. to all technician requires attending regular toolbox meeting.
Arrange required material such as cameras, cable accessories, and hand tools copy of approved shop
drawing to present.
Arrange and erect necessary scaffolding in the work area.
Scaffold to be fully inspected and tagged.
Protect the cables from civil work activates and keep the cable in a clean and dry safe area.
Informs the engineer of the work completed area to arrange QA/QC needful inspection for the
consultant. Any comments raise by QA/QC or Consultant immediately for approval of the engineer.
Prepare all the materials, equipment, and tools that will be necessary during the execution time.
Drawing for installation shall be approved and shall be coordinated with other services.
Room clearance and proper access shall be provided as per the approved program.
Ensure that the approved shop/schematic/coordination drawings are current and available with the
installation team.
Avoid installing the cameras close to sources of powerful electromagnetic radiation, such as radio or TV
transmitters or close to fluorescent lamps or objects reflecting light, or under unstable light sources,
which may cause flickering.
Ensure all the cables and conduits are reached to points.
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INSTALLATIONS DETAILS-METHOD STATEMENT CCTV
12.WIRING DETAILS
Visually inspect the cable sheath and connections of the cable.
Ensure that electrical connections are tight and grounded.
Ensure that the cable carries the correct circuit identification on size and stiffness of cable.
Verify the cables are appropriate separation according to signal type and level.
All connectors on input and output plates are labeled.
Confirm all labeling nomenclature for the area classification and correctly.
Verify all junction boxes are appropriate for the area classification and correctly.
Take reasonable precautions to prevent damage to the cable from severe blows with sharp instruments
and pulling over sharp objects.
Do not pull cables around corners that have sharp edges, such as corner in cable trays, or other
obstructions.
Make sure all equipment used during cable installation is in good operating condition.
Pre-installation inspection shall be carried out as per normal practices.
13.CCTV EQUIPMENT INSTALLATION
Transfer the cabinet to the workplace with the help of manpower. Enough manpower shall be deployed
to avoid any transportation damages.
Location of CCTV equipment rack to be as per approved shop drawing after coordinating with other
services.
Fixing holes will be marked properly keeping the backbox of the panel in place. Fix the backbox properly
and fix the remaining camera accessories.
14.CCTV CAMERAS
INSTALLATION OF FIXED CAMERAS (DOME TYPE-WALL MOUNT)
Select the location for the installation as mentioned on the drawing.
Mark the mounting hole for the wall bracket.
Drill the holes.
Remove the camera lower part enclosure and fixed into the bracket.
Push the cable into the bracket.
Fix the wall mount bracket.
Adjust the camera lens and focus.
Put the camera top cover in place.
Check that the approved cameras are installed as per the approved shop drawing locations.
Check the cameras are connected to the system using an approved type of cable.
Check proper installation of cameras.
Check that cable termination is done as required.
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Verify continuity of cable.
Trials shall be carried out only after completion of the installation.
Complete the installation checklist and the trial/pre-commissioning report.
INSTALLATION (PTZ) CAMERAS (FIXED PTZ DOME WALL MOUNT)
Select the location for the installation as mentioned on the drawing, and use the alignment sticker to
mark the position where holes will be drilled to secure the pendant head.
Mark the mounting holes for the wall bracket.
Drill the hole.
Secure the cameras to the wall mount with the set screws.
Mount the camera housing over the wall bracket.
Remove the camera lover part enclosure and fixed into the bracket.
Push the cables into the bracket.
Adjust the camera lens and focus.
Put the camera top cover in place.
Check that the approved cameras are installed as per the approved shop drawing locations.
Check the firmness of the installation.
Check the cameras are connected to the system using an approved type of cable.
Check the cable termination.
Check the camera are free to move about their axis.
Check the power connection is provided.
Final commissioning shall be carried out only after completion of the installation checklist for all the
devices in the system, and the method statement for final testing and commissioning will be submitted
separately.
INSTALLATION OF POLE MOUNTED CAMERAS
Check that the cameras are installed as per the approved shop drawing locations.
Check the provision for the camera on the pole.
Fix the camera with proper screwing.
Make sure that the data and power cable both are available.
Check the firmness of the installation.
Check the cameras are connected to the system using approved type of cable.
Check the cable termination.
Check the camera are free to move about their axis.
Check the power connection is provided.
INSTALLATION OF MONITORS
Check the monitors are installed as per the approved shop drawings.
Check the monitors are connected to the system using an approved type of cable.
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METHOD STATEMENTS
TITLE:
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MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
Check the cable termination.
Check the power connection is provided.
Final commissioning shall be carried out only after completion of the installation checklist for all devices
in the system (Method statement for testing and commissioning will be submitted separately).
Complete the setting for monitor.
INSTALL THE MOUNT
Install the camera housing wall mounting base to the smooth vertical surface or GI extension brackets.
If necessary to prevent water damage, apply sealant around the bolt holes between the mount and the
mounting surface.
Install housing into the wall bracket.
Pull the UTP cable prior to camera installation. Pull the wire (data and power) through the arm starting
from the bottom of the mounting plate; pull the wire out through the threaded opening at the bottom
of the arm.
Adjust the monitoring direction for the camera to adjust the housing in the desired direction.
Install the camera inside housing using the appropriate hardware.
Warning: Do not terminate the original UTP cable testing and commissioning.
INSTALL THE LENS
Remove the cover from the camera lens mount.
Screw the lens onto the lens mount. Be careful to prevent dust from entering the space between the
lens and the imager. If necessary, use clean, compressed air to remove any foreign matter. Make sure
the lens does not touch the camera imager when installed.
Connect the auto-iris lens to the 4-pin connector located on the side of the camera.
Plug the network cable into the RJ-45 network port on the side of the camera.
FOCUS ON THE LENS
View the camera image using the service port or a web browser.
Press the auto back focus bottom once to center the focus mechanism. The button is located on the rim
of the backbox.
Manually adjust the zoom and focus of the lens to the desired field of view.
Secure the camera using camera housing and tighten the nuts on the stud.
Identification to be made as per tagging the label was given in the approved shop drawing.
Warning: Do not terminate the original UTP cable testing and commissioning.
Note: Pulling and termination of the UTP cable shall be in accordance of structure cable pulling and
installation.
15.HEALTH, SAFETY AND ENVIRONMENT
RISK ASSESSMENT
Refer to Risk Assessment/Job Hazard analysis of the method statement for CCTV system.
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NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
PROTECTIVE AND SAFETY EQUIPMENT
All workers involved shall be equipped with adequate PPE as stated below:
• Safety helmet with company logo
• Safety boots, safety goggles, hand gloves
• High visibility vest
• Twin-tail harness, max 1m long (when working on height)
All special PPE (Harness) is considered as a last resort when we cannot engineer, administratively
eliminate, or guard against hazards.
16.INFORMATION TO PERSONNEL
• Safety Induction
• Job Training
• Superintendents
• Notices/Memos
• Toolbox Talks
• Briefings before starting work
17.EMERGENCY PROCEDURES
The contractor shall provide first aid kits on site for handling light injuries.
In the event of an emergency, all workers will be asked to evacuate and assemble at the assembly point
and wait for further instruction from supervisors.
18.PERMIT REQUIREMENTS
Vehicle permit for equipment
Working permit
Night Work
Driving permit
19.QUALITY ASSURANCE AND QUALITY CONTROL
QUALITY ASSURANCE REQUIREMENTS
The contractor shall provide the required documents for the Consultant’s approval prior to initiating the
execution of this activity as per project specification requirements.
The quality control requirement shall include related QCP’s, ITP for method statement for CCTV, and
other related documents as applicable. Refer to Inspection Test Plan.
Applicable codes and standards.
QUALITY ASSURANCE PROCESS
The contractor shall notify the engineer prior to the start of the activity and comments from the site
instruction will be complied with the satisfaction of the consultant.
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FOLLOW UP AND EVALUATION
Follow-up on quality performance shall be carried out through an in-house monitoring system such as
progress reporting to the planning department, daily, weekly and monthly reports generated by the
planning department to closely monitor site performance in general and reflect on quality performance
in specific.
All the above shall be conducted in close coordination with the quality department to monitor any
deviations from the normal quality requirement and induce corrective actions whenever required to
eliminate nonconformance or quality deviations.
All remedial actions to be taken, if any, shall take into account the official schedule which is to be used
as a guideline for performance and most importantly under the close supervision of the quality control
department.
20.RECORDS
Checklists (CKL) :
Checklist for Installation of IP CCTV
Checklist for Installation of server
Checklist for Installation of IP CCTV workstation and monitor
Note: Installation checklist from the specialist are incorporated in main checklist.
Inspection Request (INR)
Inspection and Test Record (ITR)
21.ATTACHMENTS
HSE Risk Assessment for Installation of CCTV System
Inspection and Test Plan for Installation of CCTV System
Bill of Quantity for Installation of CCTV System
Location of Installation & Reference Drawings for Installation of CCTV System
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NAME:
METHOD STATEMENT FOR
SUMP PUMP INSTALLATION
SR. EFFECTIVE REV. MSS MANAGER MSS PROJECT CLIENT
CLIENT QA/QC
NO. DATE NO. QA/QC MANAGER SUPERVISOR
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Page 713 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
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NAME:
SUMP PUMP INSTALLATION
1. PURPOSE
The Method Statement for Sump Pump defines the specified materials are installed and the agreed
procedure is implemented as per quality, project specifications, and health, safety & environment
requirements.
2. SCOPE
This method statement covers the installation procedures for the following type of GRUNDFOS Storm
Water Submersible Pumps: SLV Model
3. REFERENCES
Local Authority Regulations
Grundfos Installation & Operating Instructions for the respective pumps and controls.
IFC drawings
Approved material submittal for the submersible sump pump
4. ABBREVIATIONS
QC – Quality Control
HSE – Health, Safety, and Environment
ITP – Inspection & Test Plan
MS – Method Statement
PPE – Personal Protective Equipment
MSDS – Material Safety Data Sheet
RA – Risk Assessment
QCP – Quality Control Procedure
INR – Inspection Request
QA/QC – Quality Assurance/ Quality Control
5. RESPONSIBILITIES
PROJECT MANAGER
Responsible to manage, execute, complete and handover the construction activities within approved
budgets and resources in compliance with requirements as specified in project specifications.
He will be overall in charge of implementing Method Statement in accordance with QA/QC and HSE
requirements.
CONSTRUCTION MANAGER
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NAME:
Responsible for overall construction activities ensuring that all quality and safety procedures are
implemented.
Ensure that the required approved permits are obtained.
Managing construction activities and leading the site supervision, subcontractors and vendors to
assist them in working to the project schedule by conforming QA/QC and HSE requirements at site.
HSE MANAGER
Generally plans, coordinates and implements issues and directives within the organization.
Ensures safe environmental working conditions for all employees.
HSE SUPERVISOR
Monitors the site engineer’s strict implementation of the Method Statement for Sump Pump
Installation and Risk
Assessment.
Implements the use of proper tools and equipment to maintain safety, certifications of equipment and
their adherence to safety regulations.
Reports any unsafe work or stopping work that does not comply with HSE procedures.
QA/QC MANAGER
Establishes the proper implementation of the quality system.
Responsible for supporting the project team in implementing and maintaining Quality Management
System for the project through PQP, ITP, MST, and procedures in compliance with project specifications,
codes, and standards.
QA/QC ENGINEER
Responsible for the conduct of inspections as per approved ITP.
SITE ENGINEER
Supervises the operations in accordance with the approved Method Statement for Sump Pump
Installation, shop drawings, specifications, material submittals, and schedules to achieve the acceptance
of the project deliverables.
SITE SUPERVISOR
Supervise closely, the activities designated to them and ensure that all instructions and safety procedure
are followed.
SITE FOREMAN
Liaises with the Site Engineer and Supervisor for the work execution.
ELECTRICIANS
Responsible for assisting their superiors during all construction work-related activities.
Work in line with the HSE and QA/QC requirements.
STORE IN-CHARGE
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Receives and inspects all incoming materials and reconciles all related documents.
Processes and distributes documents tracks damage and discrepancies.
6. RESOURCES
TESTING INSTRUMENT REQUIRED
Clamp-on Ammeter
Megger, 500VDC
Digital Multimeter
MANPOWER
Construction Manager
Site Engineer
QA/ QC Engineer
HSE Officer
Supervisor
Electricians
Helpers
7. MATERIALS HANDLING AND STORAGE
The contractor & specialist MEP subcontractor are advised to ensure to take the utmost care while
loading, transporting, offloading, and all installation activities.
Pump shall be kept in a flat secluded surface with well ventilated storage area.
The unit selection, locations, and levels shall be in full compliance with the approved materials, IFC
drawings, approved shop drawings, BOQ, and project specifications including but not limited to all
supporting systems, anchoring, and spacing requirement.
Shift the pumps and their accessories to the working area in a safe manner as per site conditions by the
use of either hand trolley, forklift, or crane.
8. METHODOLOGY-INSTALLATION OF SUMP PUMP
PRE-INSTALLATION/GENERAL REQUIREMENT TO CONSIDER
Meeting shall be scheduled prior to the beginning of the work and before any sub- contractor starts on
the project.
Prior to the commencement of any construction works, the area and access will be inspected to confirm
that they are in a suitable condition for construction work to commence. Prepare a working permit (if
any) and submit it to any designated safety officer.
All relevant documentation (approved shop drawing, coordination drawing, approved method
statement, approved material submittal, approved ITP, the checklist) and material applicable to a
particular section of work will be checked before commencement of work.
The sequence of work activity shall be coordinated at the site with other disciplines and secure other
trades (Civil/structure &Architectural) to ensure smooth coordination and to avoid re-work.
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CONTRACTOR
NAME:
The mechanical site engineer will instruct the supervisor in charge who in return will relay to the
tradesmen regarding the execution of the work and will distribute all necessary approved construction
shop drawings and coordinated layout plans.
The site mechanical engineer/supervisor should also check the tools and equipment available which
should be compliant with the contract requirement and are in good and safe working condition.
Ensure that only approved materials are required to carry out the work shall be available.
Pump selection is based on the certified performance curve and rated capacity of the selected model
mentioned as per approved material submittal, project specification & design equipment schedule.
Electrical component devices and accessories shall be defied in the latest TEC Standard acceptable.
The drainage water pump must be as per the approved material submittal and project specification.
When two or more units of equipment of the same type and class shall be the product of one
manufacturer.
Pumps identifications: Manufacturers nameplate, trademark, model, serial number, GPM, TDM, 994, HD
Impeller, discharge, suction shall be fixed at each equipment.
The in-charge Mechanical Engineer, supervisor, and foreman should verify that the personnel or
assigned person must have sufficient knowledge of the procedure for the installation, operating
Instruction and necessary fundamental Information Review training and qualification record for those
individuals who will do the task to determine whether they are skilled enough to follow the procedure
before the work is carried out.
Mockup for submersible pumps (mechanical and electrical) installation complete with all hook-up details
(including all accessories and supporting arrangement) shall be carried out at site prior to proceeding.
The installer will receive a set of installation drawing from the factory with tag number and hosting shall
be executed as per the manufacturer’s recommendation.
Pump installation shall be carried out in accordance with the approved shop drawing, plan, section, and
details and as per manufacturer’s recommendation, project specification.
All safety regulations must be observed at the installation site.
9. INSTALLATION PROCEDURE OF SUMP PUMPS
EQUIPMENT SUPPORTS
The pump assembly will be mounted inside the concrete sump pit with the required supports as per
manufacturer’s recommendation and approved drawings and materials.
All required accessories shall be fixed as per approved detail drawings.
VALVES, SENSORS, SWITCHES, AND OTHER ACCESSORIES
Support installation for valves and field devices shall be followed as per the approved shop drawing
details and project specification.
Confirm that the valve schedule shall be as per the approved layout and approved material submittal
prior to installation.
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Valve shall be installed with flange and union to allow servicing, maintenance, and equipment removal
without shutting down the system and located at an accessible location.
Guide pipe should be fixed as per approved detail.
There should be one check valve and one gate valve at the pump discharge line.
Float switches shall be positioned as per approved details & shop drawings.
10.SUMP PUMPS INSTALLATION PROCEDURE
Supply and install all sump pumps wherever shown in the approved shop drawing. Assure proper hit of all
equipment and materials in the space as shown in the drawing.
Remove plug covering at pump discharge and suction ports once it is ready for fixing into drainage
pipelines.
Align the pump and piping connection on both suction and discharge ports confirm once more the pump
level and alignment once it is bolted.
Securely anchor the pump assembly with bolts to the concrete flooring or metal structure.
Make sure the weight of the pump assembly does not put a strain on the piping network, and the pump
inlet and outlet connections are installed stress-free against a heavy load.
Make sure there are no foreign materials inside the pump, and the impeller turns smoothly in the correct
direction.
Install pump’s discharge and suction pipelines with valves and accessories.
The piping flange must be accurately aligned before the bolts are tightened, and all the piping valves and
associates. Fittings should be independently supported without any strain being imposed on the pump as
it will reduce the reliability and performance of the pump, and can result in high maintenance costs.
Ensure flange type, bolts, and nuts are matching that can meet the required pump’s working pressure.
Assemble the suction and discharge pipes in accordance with the generally accepted procedure and
without exposing the pipes to distortion of tension.
Support for the pipeline shall be properly fixed and clamped, valves shall be supported as per the
approved shop drawing, plan, and details. It is always necessary to install support for the pipe on the
discharge and suction side of the unit. So that the weight of the piping does not come to bear on the
pump.
The Site Engineer/ Foreman ensures the surrounding area where the pump will be installed are free from
debris and the pump shall be protected until final acceptance of the client.
Check the direction of impeller rotation; the arrow on the pump casing shows the direction of the
rotation.
Field damage factory finish on equipment shall be touched up with paint that is equal in quality and color
to the original factory finish.
11.INSTALLATION OF ELECTRICAL WIRINGS
Provide all electrical equipment with proper wire size including connection of power supply.
Provide required power control and grounding wires for all pump motors.
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Check the connection to provide correct rotation for all pump motors.
The electrical connection should be carried out in accordance with the local regulation and
manufacturer’s recommendation.
Make sure to visually inspect the cable condition against any damage: not sharply bent or pinched.
The supply voltage, ampere, and frequency shall be marked on the pump nameplate.
Install the electrical isolator panel and power connection as per the approved drawing and method
statement.
Connect the pump’s motor cable to the control panel and monitoring equipment. Check using a multi-
function electrical tester that all wiring connections are correctly spliced and electrical buttons are
working.
12.INSPECTION
After completing the pump installation, The Site Engineer / Supervisor shall systematically check and
Inspect the work as per approved shop drawings. Any rectification modification shall be immediately done
prior to raising an INR.
After satisfactory inspection by the Site Engineer/ Supervisor on the fixed pump, the INR has to be raised
by them with complete attachment & Information regarding the scope of the inspection, including
highlighted drawings to show the scope of Inspection. The inspection shall be performed according to the
typical checklist and approved Inspection and Test Plans ( ITP ).
The needed attachment will be forwarded by the Site Engineer/Supervisor to the QA/QC Department who
shall check and process the INR documents of completed works for Supervision Consultant installation
inspection and approval.
After ensuring that safety precautions are in place, check that all pump valve packages shall be fully open
to avoid damage to the disk and seat ring.
Correct alignment, flat and smooth settling of pump shall be inspected by Site Engineer/Supervisor.
Pump’s freewheel and direction of impeller rotation as well as the fluid flow direction shall be observed;
and made sure that supplied electrical power is in – line to equipment nameplate rating.
Check nameplate and cross-check with the specifications/approved shop drawings/approved materials to
ensure the correct pump.
Check impeller to ensure free and smooth rotation.
After Site Engineer satisfactorily completed the inspection, INR shall be submitted to QA/QC Department
who shall check and process the documents to have completed work inspected by Supervision Consultant
for final approval.
13.HEALTH AND SAFETY ANALYSIS
Risk Assessment
Refer to Risk Assessment
14.PROTECTIVE AND SAFETY EQUIPMENT
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All workers Involved shall be equipped with adequate PPE as stated below:
• Safety helmet with company logo
• Safety boots
• High visibility vest, safety goggles, hand gloves, coveralls
• Twin-tail harness, Max 1.20 m long (when working at height). All special PPE (harness) is considered
as a last resort when we cannot engineer, administratively eliminate, or guard against hazards.
14. INFORMATION TO PERSONNEL
a. Safety Induction
b. Job training
C. Superintendents Notices/Memos
d. Toolbox talks
e. STARRT Card
15. SPECIAL SAFETY REQUIREMENTS
a. All necessary personal/protective equipment (PPE), as well as harness, be provided.
b. Banksman, wearing distinctive vests, shall be assigned to help operators maneuver their equipment.
c. The equipment operators shall possess the required licenses and certificates.
d. Generated dust shall be controlled by periodic water spraying.
e. The project safety officer is responsible along with the project zone site engineer for ensuring that all
operations are carried out with due regard to the safety of all project personnel & property.
f. All working activities shall comply with client safety procedures.
g. First aid material.
h. General management of protection/operation hazards is to be observed.
i. In case of working at night, please refer to Method Statement for Night
16. EMERGENCY PROCEDURES
The contractor shall provide first aid kits on site for handling light injuries.
In the event of an emergency, all workers will be asked to evacuate and assemble at the ASSEMBLY POINT
and wait for further instruction from supervisors.
Emergency Contact Numbers
In case of a serious accident, dangerous occurrence, fire, or environmental incident the Emergency
Contact Numbers shall be contacted.
17 .PERMIT REQUIRED
• Vehicle Permit for Equipment
• Working Permit
• Night Work
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18.QUALITY ASSURANCE AND QUALITY CONTROL
QUALITY ASSURANCE REQUIREMENTS
The contractor shall provide the required documents for Consultant approval prior to initiating the
execution of this activity as per the Project Specification requirements.
The quality control requirement shall include related QCP’s, ITP’s and other related documents as
applicable. Refer to Inspection Test Plan.
Applicable codes and standards for materials.
19.QUALITY ASSURANCE PROCESS
The contractor shall notify the Engineer prior to the start of activity and comments from the site
instruction will be complied with as per contract.
20.FOLLOW UP AND EVALUATION
Follow-up on quality performance shall be carried out through an in-house monitoring system such as
progress reporting to the planning department, daily, weekly and monthly reports generated by the
planning department to closely monitor site performance in general and reflect on quality performance
in specific.
All the above shall be in close coordination with the quality department to monitor any deviations from
the normal quality requirement and induce corrective actions whenever required to eliminate non-
conformance or quality deviations.
All remedial actions to be taken, if any, shall take into account the official schedule which to is used as
guidelines for performance and most importantly under the close supervision of the quality control
department.
21.RECORDS
Checklist (CL)
Inspection Request (INR)
Inspection and Test Record (ITR)
22.APPENDICES-METHOD STATEMENT FOR SUMP PUMP INSTALLATION
Risk Assessment
Emergency Contact Numbers.
Inspection and Test Plan (ITP)
Checklist
Manufactures Manual for Installation of Submersible Pump
Approved Material Submittal
Approved Method Statement for Cable Laying
Approved Method Statement for Isolator Installation
Organization Chart
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NAME:
METHOD STATEMENT FOR
TRANSFORMER INSTALLATION
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 722 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
SR. EFFECTIVE REV. MSS MANAGER MSS PROJECT CLIENT
CLIENT QA/QC
NO. DATE NO. QA/QC MANAGER SUPERVISOR
TRANSFORMER INSTALLATION
1. PURPOSE
The method statement for transformer defines the installation of oil-type transformers as per quality
procedure, project specifications, and health, safety & environmental requirements.
2. SCOPE OF WORK
The scope of this document includes, but not limited to the following:
a) Methodology for installation of transformers
b) Equipment used
c) Inspection and Test Plans
d) HSE Assessment & Job Hazard Assessment
3. DEFINITIONS/ABBREVIATIONS
IFC-Issued for Construction
SUB-Subcontractor
IR-Inspection Request
ITP-Inspection and Test Plan
HSE-Health, Safety, and Environment
PPE-Personal Protective Equipment
RA-Risk Assessment
MIR-Material Inspection request
MST-Method Statement
NCR-Non-Conformance report
QA/QC-Quality Assurance/ Quality Control
PQP-Project Quality Plan
RAMS-Risk Assessment Method Statement
PTW-Permit To Work
LV-Low Voltage (415 V)
VFD-Variable Frequency Drive
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Property of MSS – Approved (Controlled document in Document Repository)
FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 723 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
MV-Medium Voltage
SMDB-Sub Main Distribution Board
4. SEQUENCE OF WORKS
The following are the step by step procedure for the installation of transformer.
Prior to installation it will be ensured that:
a. All relevant documentation such as (Approved Shop drawings, Checklist and Approved Method
Statement etc.) and the material applicable to a particular section of work will be checked by the Site
engineer prior to the commencement of work ensuring that these are of the correct type as reviewed by
the Engineer
b. Before commencement of installation of transformer, a material inspection of the transformer will be
carried out prior to being withdrawn from the storage area i.e. quantity, physical damage and
brand/make.
c. Before the beginning of the installation, it will be ensured that the approved valid permit to work (PTW)
is available on site.
d. Engineer in charge will ensure that approval and standard tools and tackles are available to carry out
the work.
e. Safe access to work areas will be provided and will be approved by the competent safety person prior
to commencement of works if applicable
f. Check the work area tidy and remove flammable materials if any and a safe environment will be
ensured.
g. Where the Risk Assessment identifies high-risk works a permit to work will be obtained from the safety
department.
h. Competent manpower will be employed to carry out the installation work.
i. Prior to installation, It will be ensured that all the civil works are completed with the necessary
protective floor coating (if needed).
j. Necessary civil clearance will be obtained (if applicable) prior to the start of installation.
k. For loading and unloading operation, the proposed crane location to be ready with the compacted floor
for safe positioning of crane and boom trucks.
l. The boom truck loading capacity and certificates will be ensured prior to the start of the loading.
m. The transformer will be unloaded in a pre-identified place for necessary material inspections prior to
installation.
n. Once the inspection completed the transformers will be shifted and positioned by using a boom truck.
5. MATERIAL TRANSPORT
a. Transformers and other related accessories will be handled and transported and unloaded at site
strictly as per manufacturers instruction.
b. After delivery, equipment will be inspected for any transport both internal and external components
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Property of MSS – Approved (Controlled document in Document Repository)
FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 724 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
casing damage, in compliance with project specification & materials submittal.
c. The transformers and accessories will be tagged, crated, and protected for shipping as per the
manufacturer’s recommendation.
d. Approved shop drawings will be posted at the workplace for site reference used and installation works.
6. DELIVERY AND STORAGE
a. When the transformer cannot be installed immediately, Transformers and other related accessories will
be stored at a dry location in the laydown area. They will be protected and covered by polythene
sheeting.
b. The transformers will be handled with care to prevent mechanical damage to the body, fitments,
enclosures, and core-coil assemblies.
c. The transformers are factory packed for transport and will be protected as per manufacturers’
instruction.
d. Check for the transformer packing for any damages while transportation will be done.
e. A material delivery to the site will be inspected for delivered equipment for approval from the
engineer.
f. On receipt of the transformer, It is necessary to carry out the following check:
1. To check there are no signs of damage on packing or the transformer occurred probably during the
transport.
2. The characteristics of the transformer detailed on the rating plate must correspond to those of the
shipping documents and with those of the test report, which is attached to the transformer.
3. Check the nameplate details against the technical datasheet to confirm the correct materials.
4. To check that each transformer is complete with the accessories foreseen in the contract (wheels,
thermo-controller, etc.).
g. All the delivered spare parts as per project specifications to be stored properly till handover.
h. The transformer should not be placed, close to the ground where water might accumulate. In such
cases, the transformer should be placed on wooden or similar beams in order to prevent rust formation
due to scratches and contact with wet soil/ground directly.
i. Any discrepancies, damage, and etc, found to the materials will be notified and reported to QA/QC
Engineer.
j. Materials found not suitable for site use will be removed immediately.
k. No materials will be permitted to enter the work location without being inspected and approved by the
Engineer.
7. HANDLING
a. During the transport or the handling, only the recommended special lifting eyes and tow attachments
are used.
b. All lifting equipment will be rated for the purpose, checked for damage, and certified by a third party
before any attempts are made to lift the transformers.
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
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Page 725 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
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NAME:
c. If a crane will be used to lift the equipment, it will be ensured that the slings are harnessed in such a
way that the equipment is centered to the gravitational force to avoid wobbling and jerking which may
cause fatal and serious troubles in unloading.
a. For lifting the upper frame of the transformer is complete with lifting eyes for slings. Lift with a
maximum sling angle of 60 degrees.
b. Always move the transformer in its upright (top end up) position.
c. Lifting operations will be performed by trained people for using cranes.
d. Lifting will also be performed by a forklift with sufficient capacity if the transformer is placed on a
pallet. It will be operated by a trained person.
e. For movement by forklift the position of the forks under the bottom clamping profile will be as far apart
as practicable. This has to be lifted only a small amount above the floor surface at all times during transit.
f. The transformers cannot be moved to push the coil and the connections.
g. Care will be taken by the site team that no tools or bits of metal hardware are dropped into the coils or
not damage the cast resin during handling and installation.
8. METHODOLOGY
TRANSFORMER INSTALLATION
a. It will be ensured that installation of the liquid-filled medium voltage transformers will be strictly in
accordance with the manufacturer’s recommendations, as per approved shop drawings, relevant IEC
(International Electrotechnical Commission) standards, and project specifications.
b. It is ensured that the access is clear to shift the transformer. The substation doors are checked to
ensure that the door openings are enough to move the transformer inside the substation.
c. The transformers will be unloaded adjacent to the respective substation.
d. Move the transformer manually to the transformer location.
e. For manual handling, rollers are used to facilitate forward motion to find the erection place.
Note: The transformer should not be moved by pushing the coils and connection.
f. After the transformer positioning, all wheels will be locked to arrest any movement of the transformer
by providing the necessary stopper.
g. Recommended shims will be installed if required for transformer leveling.
h. All the incoming and outgoing cable supports, cable ends and termination fittings required for MV, LV,
and control cables will be installed.
i. Inspection request for transformer installation prior to the start of any cable termination work will be
done.
j. The transformers will be mounted on wheels.
k. The transformer skids shall have rounded off beam ends and shall be provided with pulling lugs/holes
to enable site movements.
l. It will be ensured that concrete bases and foundations provided for installation of equipment are
constructed in accordance with approved shop drawings, construction drawings, and equipment
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 726 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
manufacturer’s drawings. All the holes for fixings bolts and provisions for passage of cables etc. are
provided as required.
m. It will be ensured that trench construction and covers provided for installation of power and control
cables are in accordance with approved shop and construction drawings.
n. The installation of cables, wires, raceways, supports, cable ends, and termination fittings will be done in
accordance with the appropriate sections of the project specification and/or as shown on the approved
shop drawings. All the electrical connectors and terminals will be tightened according to the
manufacturer’s published torque-tightening values.
9. CABLE CONNECTIONS
CABLE CONNECTING BOXES
a. The cables which are connected to the transformer will be fixed properly to avoid any mechanical stress
on the transformer terminals.
b. Cable connecting boxes shall be made of steel and shall be dimensioned to allow termination of the
specified cables.
c. The enclosures will be offered a minimum degree of protection IP55, in accordance with IEC 60529 and
as per project specifications.
d. The cable ends should be flexible enough to prevent mechanical strains that could be caused by
expansion and contraction, which could break the isolators, when available.
e. Contact surface of the cable terminations will be checked. If it is necessary, it will be brushed and wiped
with a dry cloth.
f. Separate cable connecting boxes shall be provided for the connection of the specified cables to:
1. Medium – voltage side of the transformer
2. The low – voltage side of the transformer
3. The transformer auxiliary circuits (direct measuring alarm/ trip devices, CT secondaries, etc.).
4. The off-load tap changer.
g. Auxiliary and low voltage cable connecting boxes shall be air-insulated as per project specifications.
h. The covers of all cable boxes will be secured, using non-loosening bolts or screws. The cover of all cable
boxes will not be removable without the use of tools.
MAIN CABLE CONNECTING BOXES
a. Minimum clearance between the live metals of different phases: 127mm.
b. Minimum clearance between live metal and earth: 76mm.
c. Minimum creepage distance over insulator: 127mm.
d. Connection boxes for multicore cables shall be of a type that minimizes the cable bending requirements
(e.g. split type box).
e. Gland plates shall be constructed from a non-magnetic material.
f. M.V. and L.V. cable boxes shall be positioned on the sidewalls of the transformer. Top-mounted cable
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
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METHOD STATEMENTS
TITLE:
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Page 727 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
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boxes are not acceptable as per project specifications.
g. All cable connections shall be by a combination of Elastimold type bushings and elbow connectors as
per project specification.
h. Cut cable to length and prepare end for glanding. Adopt reducer rings and fit the cable if needed.
i. Prior to installation of cable, check the necessary cable tray/ladder are ready for cable laying and obtain
the necessary civil clearance.
FINAL WORKS
a. On completion of the installation, inspect components
b. Wipe all the bushing insulators of the bus bars and the current transformers of the connection
compartment using a soft, lint-free dry cloth.
c. The bushing type insulators and the current transformers must be free of grease and other
contamination.
d. It will be ensured earthing completed as per requirements.
e. It will be ensured that the work area will be clean after completion of works.
IDENTIFIED HAZARDS/RISKS AND CONTROL IN PLACE
The Job Hazard Analysis identifies the hazards and the safe systems of work to be followed when
conducting the activity.
10.EMERGENCY PREPAREDNESS
The Project Manager & Project HSE Manager shall ensure that all employees are aware of the correct
response to various emergency situations.
The response guidelines applicable for these works are the following:
Upon discovering the incident, take the time to assess the situation to make the area safe and to prevent
further injury to those involved. Take appropriate precautions according to the type of damage and cause
of accident like:
VEHICLE ACCIDENT
a) Switch off the vehicle’s ignition and warn the people not to smoke.
b) Make use of bystanders to control traffic or crowds, to call for help, and if they are capable, to assist
with first aid.
ELECTRICAL ACCIDENT
a) Switch off the current or break contact between the injured person and the power source.
b) Do not touch the victim or any live wires! Use non-conducting material, such as dry sticks to remove
wires from the casualty.
c) Ensure that the current is turned off or that loose wires are kept at a safe distance until the casualty is
removed to the safe area.
d) Do not approach fallen high-tension power lines until a power company official gives permission.
e) Apply artificial respiration if necessary.
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METHOD STATEMENTS
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Page 728 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
MACHINERY ACCIDENT
a) Shut off running or moving machinery
GAS, SMOKE AND POISONOUS FUMES
a) Shut off the source and remove the casualty to fresh air.
b) Do not enter a confined space and become another victim.
FUELS & OIL CHEMICAL SPILLS
a) Switch off any likely sources of ignition.
b) Build a bund or dig a hole to contain the fluids.
c) Contain the split material and isolate the area.
CHEMICAL SPLASH/CHEMICAL INHALATION
a) First Aider shall be available at the work location.
b) First Aid Box shall be placed at the work location.
c) Use eyewash in case of a chemical splash on the face or eyes.
d) Shift the patient to the well-ventilated area in case of chemical inhalation.
e) Call for paramedic assistance or the affected person or shall be shifted to the clinic as required, in any
type of emergency.
f) Shift the patient to the hospital if required.
ELECTRICITY
a. Before using an electric tool, check the tool and its plug and connecting cable.
b. Do not use damaged tools.
c. Do not use an electric tool unless its connecting cable is well protected.
LOAD SHIFTING MACHINERY
a. Unless you are a worker concerned, do not work in an area where a lifter, crane (mobile/tower), etc. is
in operation.
b. Do not operate any load shifting machinery without training and approval.
c. Operators of forklift trucks, bulldozers, loaders, excavators, trucks should possess appropriate
certificates/ Passes.
PORTABLE POWER TOOL
a. Power tools inspection program will be in place with periodic training and skill development for
operators.
b. Where ever possible battery-operated tools or 110V power tools will be used which will reduce the risk
levels.
PERSONAL INJURY INCIDENT
Do not panic, the first priority in the case of any accident is to obtain proper medical assistance for the
victim. The following steps should be followed in the event of an accident.
a. Upon discovering an accident, call to attract the attention of others nearby to assist and ensure any
injured person is no further danger.
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FORMATE ID:
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METHOD STATEMENTS
TITLE:
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b. Assess the hazards at the scene and make the area safe for yourself, the victim, and others.
c. Typical hazards to be aware of are; live electrical lines, moving equipment or machinery, traffic,
hazardous chemicals, and fire. Only moved the victim if they are in immediate danger.
d. Send someone to call for emergency help. Locate the nearest First Aiders or any personnel trained in
first aid. If no available qualified personnel, locate the nearest radio or telephone and call the office or
ambulance.
INFORMATION REQUIRED FOR AMBULANCE ASSISTANCE
a. Circumstances of the incident and condition of the victim(s).
b. Number of casualties involved.
c. The exact location of the accident.
d. Help that has been given or is being given.
e. Name and telephone number from which the call is being placed (if applicable).
f. Wait to be told what to do before hanging up the call.
g. Protect and shelter the victim until medical help arrives and post somebody at the site entrance to
direct the ambulance to the accident.
h. Immediately after attending to the victim, the Project HSE manager or crew supervisor shall complete
an Accident Report.
i. In the case of fatal accidents, the Police and the nearest HSE Authorities shall be informed immediately.
FIRE
Raise the alarm at once. Proceed to the nearest telephone or radio and ask whoever is present to call the
fire services or do so yourself. Attack the fore with correct firefighting extinguishers or other suitable
firefighting equipment.
A roll call of all employees shall be taken when premises have had to be evacuated. Each section shall
nominate a Fire Warden who, in case of an emergency shall undertake the following duties:
a. Keep a check of personnel movements so that an accurate roll call can be made.
b. Alert the remainder of the office of the emergency.
c. Supervise the orderly exit as per the emergency exit plan.
d. Check the staff numbers.
e. Ensure the personnel does not leave the assembly area until counted.
f. Advise emergency services if any person remains unaccounted for. The emergency exit plan shall be
prepared by the HSE Manager and will show the positions of all exits.
11.ENVIRONMENTAL CONSIDERATION AND IMPACT CONTROL MEASURES
WASTE MANAGEMENT
Good waste management practice is essential in order to achieve regulatory compliance. It can also lead
to improved business efficiency and cost savings. The following waste management practices will ensure
the preservation of environmental resources.
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a. Waste should be reduced and recycled where possible.
b. Water drained after pressure testing shall be collected and reused for curing or damping down the
dust.
c. Disposal area should be well prepared to receive the waste. And all waste areas and containers should
be landed with their content.
d. All containers must be in good conditions, not leaking, and stored on hard standing.
e. Do not allow containers to overflow and remove them regularly.
f. Do not dispose of burn, bury or treat waste on-site.
g. Do not mix regulated and non-regulated wastes.
h. Wastes cannot be disposed directly to landfills or to the sea unless it meets the local regulatory
authorities.
i. Untreated sewage shall not be disposed of without treatment. At the site, it shall be confined in septic
tanks and removed via sewage tankers and disposed of in an approved location.
j. The emergency procedure described earlier shall be applied in any case of chemical spillage.
k. All chemicals and environmentally hazardous material shall be isolated by storing them within bund
walls on top of paving pads to prevent any leakage into the water table.
l. In case of dewatering and unsuitable water is encountered, the engineer’s site representative shall be
immediately notified to advise further course of action.
NOISE CONTROL
a. Use silencers for high noise generating equipment whenever possible.
b. Regular maintenance of equipment and machinery.
c. Wear earplugs if the workplace noise level exceeds 85 dbA for TWA 8 hours.
d. Noise level to be measured and recorded every day at the workplace.
e. Avoid dropping materials like scaffold accessories and plywoods at the work area.
DUST CONTROL
a. Regular water spraying on unpaved roads to avoid dust dispersion.
b. Limiting the speed at the site to 20 Km/h.
c. Maintenance of roads whenever required to alleviate dust accumulation.
d. Vehicles, machinery, and equipment control.
e. Regular maintenance of vehicles, machinery, and equipment to avoid excessive smoke emissions.
MANDATORY PPE FOR THE WORK ACTIVITY
PPE is the last line of defense not the first: however, every contractor should provide adequate
suitable, sufficient PPE to protect the workforce wherever possible. As a minimum for all
personal during the abutment works will be the hat, safety boots, coveralls, goggles, and gloves will
be provided and used at all times. Additional task-specific PPE will be provided and worn in line
with risk assessments.
EMERGENCY PROCEDURES
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This procedure describes the company’s guidelines on emergency responses to ensure prompt
and safe action is taken. This procedure applies to all health, safety, and environmental
emergencies with particular emphasis on the company’s requirement in the event of personal
injury accidents or fire emergencies.
12.GENERAL
The Project Manager in coordination with the Project HSE Manager shall ensure that the project has in
place a viable and up-to-date Emergency Response plan. This plan shall include allocated responsibilities,
contact detail for project personnel, contact details for local authorities, contact details for group
personnel off-site, emergency response action, and maps as a minimum.
13.COMMUNICATION
As a minimum HSE manager shall ensure that HSE communication Flow and Emergency Telephone
numbers are complete, kept up to date, and circulated on Project HSE Notice Boards. The PM with close
coordination with the HSE manager shall take all necessary steps to ensure that this information is
communicated and understood by all employees and sub-contractors working on site. It takes all
necessary steps to ensure that the workplace has adequate reliable means of communication internally
and as required outside communication.
14.EMERGENCY RESPONSE
The emergency response shall be initiated by Authorized Person. Emergency response as per the HSE plan
shall be followed.
In case of an emergency, the following actions shall be activated: Stop the activity.
Call the emergency number for help.
Provide first aid and call an ambulance.
Alert site clinic / Nurse/ First aider.
15.QUALITY CONTROLS
The Inspection and Test Plan (ITP) for this Method Statement For Transformer Installation summarizes
various characteristics to be checked. The concerned Site Engineer or Site Supervisor will be responsible
to ensure compliance for these operations and the site QA/QC Engineer will carry out quality control
checks and report the inspection results.
QUALITY RECORDS
Quality records will be provided as identified in the ITP and maintained as per ISO 9001/2015 & Standard
form of records, quality checklists, and QA/QC reports requirements are defined in the Inspection and
Test Plan.
Submission of as-built records will be done after completion.
SPECIFIC QUALITY MEASUREMENTS
a. All works will be undertaken in compliance with the quality requirements of the Contract and “Project
Quality Management Plan”. Where non-conformances are found/identified to demonstrate its
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conformity. All works requiring inspection and testing to demonstrate conformity with requirements will
be undertaken in accordance with the “Control of Inspection and Testing”.
b. Where non-conformities are found/identified, they will be addressed in accordance with “Procedure for
Control of Non-Conformances”. The quality control activities associated with the works will be conveyed
to all personnel involved in the execution of the works by the Project QA/QC Manager prior to the
commencement of the work.
c. The equipment and instruments used for measurements on-site will be calibrated and certified. The
relevant documents will accompany the corresponding equipment and instruments. Necessary internal
and external training are provided to the staff carrying out the job to ensure that the quality standards
required on the project are met. Skilled and competent personnel are deployed to undertake the job.
16.RESOURCE PLANNING
PROJECT MANAGER
a. Project Manager (MEP) will be responsible to manage, execute, complete and handover the
construction activities within approved budgets and resources in compliance with Project requirements
as specified in Project Specifications. He will be overall in charge of implementing the method statement
for transformer installation in accordance with QA/QC and HSE requirements.
b. Responsible for controlling the project’s entire activities & for the overall coordination with the
consultant/client.
c. Ensure that adequate welfare facilities and equipment are provided to the project to avoid injury,
health impairment, or damage & to ensure providing quality works within the planned time scale.
d. All responsibilities stated in the Project’s Quality Assurance Plan.
CONSTRUCTION MANAGER
a. Organize the site so that work is carried out to the required specifications with minimum risk to men,
equipment, and materials.
b. Coordination with different functions with the project.
c. Expediting area of concern to achieve project schedule.
d. Adhere to the project-specific quality management program and HSE requirements.
e. Delivering the overall works in a safe and timely manner, ensuring conformance with the approved
design. Leading the team of engineers and surveyors, guiding them in the delivery of the works. Acquire,
allocate and maintain resources.
QA/QC MANAGER
a. Responsible for the work of entire quality assurance, quality control & inspection programs.
b. Produce all quality-related documents & reports necessary as requested by the
Owner/Consultant/Engineer.
c. Provide written procedures & to coordinate in formalizing the Method Statements with the Project
Manager/ Construction Managers/Site Engineers to describe the job-specific work for each stage/activity.
d. All responsibilities stated in the Project’s Quality Assurance Plan.
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TITLE:
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QA/QC ENGINEER
a. Responsible for the work of entire Quality Assurance, Quality Control & inspection programs.
b. Produce all Quality related documents & necessary quality reports as requested.
c. Provide written procedures & coordinate in formalizing the Method Statements with the Construction
Manager/Site Engineers to describe the job-specific work for each stage/activity.
d. Will make sure that all the works mentioned in this method statement will carry out in approved shop
drawings and as per the project specification.
e. Will make sure IR for all these activities are raised and approved by the consultant and recording those
documents for testing, commissioning, and for handing over the procedure.
SAFETY MANAGER
a. Manage Safety Engineers and Safety Officers to be in strict conformance with project policies and
procedures.
b. Must ensure safe work method of stated in the method statement for transformer installation and RA
is fully implemented during activity.
c. Responsible for controlling HSE personnel for effective monitoring of work.
d. Over-see site safety orientations/inductions, toolbox talks, safety training certifications, job site
inspections, working at heights, scaffolding tagging systems are fully functional, rigging, etc.
e. Report to Project Manager all personal injuries and near-miss incidents (aligned with Safety
Engineers / Officers) as well as property damages immediately. Produce investigative reports and
summaries to senior management.
SAFETY OFFICER
a. Provide advice and coordination in line with the project HSE Plan, legislation, and standards to
workgroups as required/directed.
b. Input into the preparation and maintenance Risk Register at the project level which will form the basis
of risk management on the project for the RAMS.
c. Monitoring and reporting compliance with the Project HSE Plan.
d. Conducting regular HSE inspections and participating in HSE audits.
e. Reporting as required, HSE incidents, including near-miss events, injuries, and any other HSE issues.
f. Regularly attending toolbox and other HSE meetings.
g. Will ensure that the work site has been examined, and all precautions specified to be taken in the PTW
before work commences have in fact been taken.
h. Will ensure that the works are examined on completion of the works and the PTW is correctly closed.
SITE ENGINEER
a. Adheres to the project-specific method statements, procedures, inspection programs & HSE
instructions to get the activities performed to Client satisfaction with full coordination with the HSE &
Quality personnel.
b. Responsible to ensure that correct drawings, materials, tools, and equipment are provided site.
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c. Liaising with sub-contractors, supervisors, planners, quantity surveyors, and the general workforce
involved in the project.
d. Responsible for planning the work and efficiently organizing the plan and site facilities in order to meet
agreed-on deadlines.
e. Site engineer is responsible to coordinate with QA/QC Team engineers/ inspectors, and to handover
daily site progress works report/highlighted drawings & present during inspection/site visit with QA/QC
Inspectors & consultant/client.
FOREMAN
a. Performed the activities instructed by the Supervisor/Engineer at the site and follow the safety
procedures to make it safe for his workers.
b. In charged to lead the work execution send the focal point in coordinating with the site
Supervisor/Engineer related to overall site activity, materials, tools, and equipment.
TECHNICIAN
a. Carry out Installation work as per the concerned foreman’s instructions with all the safety
requirements.
b. The workforce to attend daily toolbox talks, morning task brief briefs prior to starting any works EHS
(Environment Health Standard) plans and policies.
WORKFORCE
a. Carry out their work in such a way that they don’t create for themselves or any other person risk to
health safety, and don’t impact the environment to the maximum extent possible or affect the quality of
work.
DOCUMENT CONTROLLER
a. Documenting, distributing, and maintaining data in the prescribed format.
b. Making the necessary data available as requested by the team or the client.
17.TOOLS AND EQUIPMENT
a. Hand tools box (Spanner set, cutting pliers, tube cutter, screwdriver set, hammer, hacksaw frame & flat
file, cleaning brush, spirit levels)
b. Adjustable wrench
c. Splice kit
d. Mobile scaffold
e. Ladder
f. Pallet jack
g. Drilling machine
h. Crowbars
i. Torque wrench
j. Plumb bob, nylon thread
k. Heavy air compressor/vacuum cleaner
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l. Sling ropes
m. Ratchet and spanners-various sizes and extensions
n. Crimping tool
o. 3rd party certified lifting equipment (Chain pulley, A-frame chain hoist and etc.)
p. Boom truck
q. Forklift
The foremen and engineers on-site will ensure that all necessary equipment is available as well as fit and
safe prior to commencement of work.
All above equipment will comply with:
a. All Equipment used on the works will have a valid certificate of operation provided by a recognized
licensing authority.
18.REFERENCES
a. Project Specifications
b. Approved Shop Drawings
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METHOD STATEMENT FOR
STANDPIPES, SPRINKLER PIPES &
ACCESSORIES INSTALLATION
SR. EFFECTIVE REV. MSS MANAGER MSS PROJECT CLIENT
CLIENT QA/QC
NO. DATE NO. QA/QC MANAGER SUPERVISOR
STANDPIPES, SPRINKLER PIPES & ACCESSORIES INSTALLATION
1. SCOPE OF WORK
This Method Statement for Standpipes, Sprinkler Pipes, and Accessories defines the execution for
installation in accordance with the relevant reference standards, project specifications, approved shop
drawings, and health, safety & environment requirements. The contractor shall ensure that the safe work
systems resulting from the Risk Assessments are employed throughout the works described in this
method statement. The Construction Manager and Safety Manager both have the responsibility for
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ensuring that the method statement procedures are adhered to and are verified using the Site Activity
Day Diary Sheets (SADD)’s.
2. DEFINITIONS AND ABBREVIATIONS USED
The following definitions and abbreviations are used in this Method Statement for Standpipes, Sprinkler
Pipes, and Accessories:
AC Alternating Current
CDM Construction Design Management
CP Competent Person
GI Galvanized Iron
GSAS Global Sustainability Assessment System
HSE Health Safety and Environment
ID Identification Details
IFC Issued For Construction
I/O Input/output
ITP Inspection and Test Plan
LED Light Emitting Diode
MCP Manual Call Point
MEP Mechanical Electrical Plumbing
MS Method Statements
MIR Material Inspection Request
NCR Non-Compliance Report
NFPA National Fire Protection Association
PE Project Engineer
PPE Personal Protective Equipment
QC Quality Control
RA Risk Assessment
RAMS Reliability Availability Maintainability
SADDS Site Activity Day Diary Sheets
3. REFERENCE DOCUMENTS
Standard NFPA 13 2016 Edition – Standard for the installation of sprinkler systems
Standard NFPA 14 2016 Edition – Standard for the Installation of Standpipe and Hose Systems Standard
for the Inspection, Testing
Standard NFPA 25 2017 Edition – Maintenance of water-based fire protection system
Project Specifications – Fire Alarm and Detection Systems
Project Quality Plan
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4. HEALTH, SAFETY AND ENVIRONMENT
All site operatives will be required to undergo site safety induction and suitable training prior to
undertaking any site construction works. As a minimum, the following PPE will be provided in addition to
that identified in the Risk Assessment:
a) Safety Glasses
b) Safety Helmet
c) Coverall
d) Safety Shoes
e) Hand Gloves
f) Brazing apron
g) High Visibility Vest
h) Safety Harness
SPECIFIC
The Health and Safety considerations included in the Method Statement for Standpipes, Sprinkler Pipes,
and Accessories Installations:
1. Issue approved Method Statement & Risk Assessment to supervisors operatives prior to the work
commencement.
2. Conduct daily task briefing and toolbox talks before starting work and record all participants by signing an
attendance sheet and recording in SADD’s
3. Obtain confirmation from Main Contractor that the designated construction areas have safe access and
that all related safety precautions and safety warning measures have been implemented.
4. Provision of shaded rest areas where practical on-site and welfare facilities.
5. Provision of Drinking water, toilets, and washing in stations.
6. Daily compliance of the working practices stated in the Method Statement for Standpipes, Sprinkler Pipes,
and Accessories Installations will be managed by using the SADD inspections. Daily audits will be
conducted by the Site Engineer and HSE Inspector throughout the duration of the works.
7. Site-Specific Risk Assessment.
ENVIRONMENTAL
The Environmental Threats Risks Issues and Concerns shall also be managed using the
SADD during the works: The main environmental issues include :
1. Noise disturbance
2. Waste management
3. Lighting
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4. Dust Control
5. QUALITY
The Inspection and Test Plan for the installation of the standpipe, sprinkler pipe, and accessories
summarizes the specific characteristics and objectives that are to be satisfied. The Site Construction
Manager will be responsible to ensure stage-wise compliance for these operations, and the QA/QC
Engineer will carry out quality control checks and report the inspection results. The ‘Review/
Witness/Hold Points’ are identified in the ITP.
6. RESPONSIBILITIES FOR METHOD STATEMENT FOR STANDPIPES, SPRINKLER PIPES AND ACCESSORIES
INSTALLATIONS
PROJECT MANAGER
Responsible for for providing adequate resources and ensuring that the project specifications and
regulations are adhere to.
SR. MEP ENGINEER
Oversee the entire MEP construction activities within the site and ensure that activities are carried out as
per the contract drawings and documents and report same in SADD’s.
MEP CONSTRUCTION ENGINEER
Supervise the subcontractor to meet the desired quality of the activities and ensure that proper work and
schedules are met.
SITE ENGINEER
Supervise closely, the activities designated to them and ensure that all instructions and safety procedures
are followed and strictly adhered to.
QA/QC ENGINEER
Conduct surveillance and inspection duties at various stages to ensure compliance to QA/QC Plan.
HSEMANAGER
Provides advice and support in the application of this procedure and monitors the effectiveness of the
relevant control documents.
HSE OFFICER/ INSPECTOR
Ensure enforcement of safety procedures in accordance with the Main Contractor HSE Plan /Procedures &
Project Specifications. Record any site NCR’s in SADD’s.
7. MATERIAL TRANSPORT, HANDLING & SITE STORAGE
All materials will be delivered on-site by truck/trailer. Subcontractor will notice for any material delivery
within 48 hrs. All incoming materials will be off-loaded by crane/boom truck on the dedicated area.
On receipt of standpipe and sprinklers and accessories, the materials shall be handled and stored in line
with the following procedure:
A) UNLOADING FROM THE TRUCK
Pipes are to be checked on unloading. Possible damages must be reported on the delivery note.
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When unloading with cranes/ Boom truck The lifting belts must be placed outside around the pallets and
outside the base timber
Steer the pallets manually to prevent them from colliding with anything.
Do not move the pallets on the truck with the aid of levers or crowbars.
Do not allow the pipes to be impacted by any hard object (e.g. crane hook, chain, etc.).
All materials received at the site will be inspected by QA/QC Engineer to ensure that the materials are as
per approved material submittals in terms of their make, model type, country of origin, and capacity.
Primer and paint shall not be applied prior to the inspection.
Pipes will be stacked on a flat surface free from sharp projections, stones, or other objects likely to
caused point loading or pipe deformation.
Pipe shall be stored in a place free of water, dust and adequately covered to avoid any kind of damages
The storage area shall be kept at the proper level, so that the stacked pipes may be uniformly supported
throughout their length.
Materials received at site shall be inspected randomly and ensure that the materials are as per approved
material submittals.
Pipes will not be dropped on hard surfaces and will not be dragged along the ground. Wherever possible
the loading and unloading of pipes will be carried out manually by hand.
If mechanical lifting equipment is used, ensure no metallic slings, hooks or chains will be used in direct
contact with the pipe. A rope or nylon belt sling will be preferred which will not damage or cut the pipe
surface.
Pipe of different sizes or wall thickness will be stored separately or where this is not possible, those with
larger diameters and/or thicker walls will be placed at the bottom of the stack.
The stacks will be protected from direct sunlight by covering with tarpaulin sheets.
All other items such as valves, fittings, gauges, etc. shall be kept on racks within site stores and shall be
segregated based on size, model, type, etc. for easy retrieval.
All the pipe fittings will be stored in the boxes as supplied by the fittings manufacturer.
Any discrepancies, damage, and etc. found to the materials will be notified and reported to QA/QC
Engineer and Project Engineer for further action.
Materials found not suitable for site use should be removed from the site immediately.
While unloading, shifting, and storage, it should be ensured that there are no damages.
Do not put the pallets down onto the hard ground with a bang.
Put the pallets down only on the ground that is sufficiently hard to prevent the base timber from sinking
into it.
Leave sufficient space between individual pallets.
To avoid damage to the sealing elements, store individual pipes only on a wooden base.
Store fittings standing upright on their sockets.
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Manufacturer’s recommendations for storage/ transportation of the documents, country of origin,
delivery notes and test certificates, etc.
Raise MIR for client approval.
B) WORKSHOP STATION
A workshop must be established to allow cutting, threading, and grooving of pipes on the site for a slight
adjustment.
The workshop station must equip with a fire extinguisher and fire blanket.
Adequate illumination must be provided with a proper barricade and signage.
Workshop equipment is composed of the grooving machine, threading machine, welding station, bench
vise, working table, grinder, electric drill, and hand tools.
c) All documents will be available with the all materials & accessories. i.e. shipping.
8. PRE-SITE WORK
Prior to the commencement of any installation works associated with the standpipe and sprinkler system.
The MEP subcontractor will ensure that all site installation preconditions have been satisfied. These
include a site inspection to verify that the site condition is considered suitable for work to commence and
that the main contractor safety provisions have been provided and also completed by subcontractors
safety provisions. E.g. Site Access Site Illumination etc.
Prior to installation the subcontractors shall ensure that:
All materials and documentation relevant to a particular section of works have been checked by the
site/project engineer prior to the commencement of work ensuring that these are of the correct type as
reviewed by the client.
Before commencement of any construction works, pre-inspections will be carried out on all materials
prior to being withdrawn from the storage area i.e. quantity, physical damage, brand/make and tag.
Civil clearances shall be given by the main contractor prior of start MEP services installation.
Installation activities will only commence when all associated works by the civil discipline have been
completed.
Works shall not proceed until an approved IFC stamped shop drawing or detail is issued.
Ensure that competent & trained electricians will do the installation to ensure the best quality of
workmanship. Toolbox talk & training will be provided by Site Engineer as and when required. An
electrician certificate will be provided before any works start at the site.
Safe Access to work areas shall be provided and shall be approved by the competent safety person prior
to commencement of works if applicable.
Check the work area to be tidy and remove flammable materials if any. Ensure a safe environment.
The Site Engineer/Supervisor will also check that the tools and equipment available are in compliance to
contract requirements.
Where the RA identifies high-risk works a permit to work must be obtained from the safety department
and entered on SADD’s.
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Before and during the installation works, the study of the shop drawings, manufacturer details&
specifications must be done.
The subcontractor shall carry out a survey of the site related to the area of the installation works. This
shall include a dimensional survey, recording the construction of the building, the detail, and nature of the
existing obstruction, and future installations and maintenance, in order to fully coordinate the work to be
done.
9. TOOLS AND EQUIPMENT
The following tools and equipment items have been identified for the installation of fire alarm and
detection system :
1. Hand Tools Box ( spanner set, cutting pliers, tube cutter, screwdriver set, hammer, hacksaw frame & flat
file, cleaning brush, spirit levels)
2. Measuring tape, and suitable materials for marking
3. A-type ladder
4. Mobile type scaffolding with wheel safety lock
5. Threading and grooving machine.
6. Pipe cutter.
7. Electric drilling/ hammering/ grinding machines
8. Scissor lift, man lift and etc.
9. Clean cloth
10. Chalk line reel with powder
11. Boom truck
12. Scissor lift with sky rack
13. Manual pipe lifter
10. INSTALLATION OF STANDPIPES, SPRINKLER PIPES AND ACCESSORIES
1. GROOVING AND THREADING OF PIPES
1.1 GROOVING OF PIPES
Before grooving the pipe, make sure the setting of the groove machine is being followed properly.
Connect the tool to an internally grounded electrical source. When roll grooving pipe that exceeds the
maximum length, a roller-type pipe stand must be used.
The roller stand must be capable of handling the weight of the pipe while allowing the pipe to rotate
freely.
Place the Pipe Stand at a distance slightly beyond half the pipe length from the tool. Make sure the tool
is level.
Position the pipe stand approximately 0-1/2 a degree to the left for the tracking angle.
Refer to the drawing. Note: when pipe flare is excessive, right-to-left trucking must be kept to a
minimum. It may be necessary to use less than 1/2 a degree for the tracking angle.
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If the tool is properly set up in a level position, but the back end of the pipe is higher than the end being
grooved, the pipe may not track, in addition, the excessive flare may occur on the pipe end. Refer to the
manual setup section and the for the tool setup and pipe positioning requirements.
Before grooving, make sure all instructions in the sections of the manual have been followed.
Connect the tool to an internally grounded electrical source.
Depress the safety foot switch momentarily to ensure the tool is operational. The lower roll should be
rotating clockwise when viewed from the front of the tool.
Remove foot from the switch.
Open the valve on the hydraulic hand pump turning it counterclockwise to allow the upper roll and arm
to move to the full up position.
Insert a length of pipe that is the correct size and thickness onto the lower roll. Make sure the pipe
contacts the lower-roll backstop flange completely. Remove hands from the pipe.
Close the valve on the hydraulic hand pump by turning it clockwise.
The operator should be positioned on the safety foot switch/hydraulic hand pump side of the tool, as
shown above. Pump the handle of the hydraulic hand pump to bring the upper roll down into firm
contract with the pipe.
Depress and hold down the safety footswitch. The pipe will begin to rotate clockwise when viewed
from the front of the tool. As the pipe rotates, begin forming the groove by pumping the handle of the
hydraulic hand pump slowly.
Do not pump the handle of the hydraulic hand pump too fast. The rate should be sufficient to groove
the pipe and maintain an audible, moderate-to-heavy load on the motor/drive.
Continue the grooving process until the depth adjuster lock comes into contact with the top of the tool
body. Continue pipe rotation for several revolutions to ensure groove completion.
Release the safety footswitch, and withdraw foot from the switch.
Open the valve on the hydraulic hand pump by turning It counterclockwise to release the pipe. Remove
the Pipe from the tool.
If no more roll grooving will be performed for a while, disconnect the tool from the electrical source.
The groove diameter must be within specification for the diameter and wall thickness of the pipe. The
groove diameter should be checked and adjusted, as necessary, to ensure grooves remain within
specification.
1.2 THREADING OF PIPES
A die head will be attached to cut the thread.
The machine now has the ability to threads pipes.
A heavy-duty pipe threader can also cut your pipe into workable sections.
The pipe threading machine will be used to thread the end section of your pipe.
Inspect the pipe threader before beginning and replace dies or any parts that show signs of wear.
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Mount your pipe firmly in the pipe vise by placing it in the vise and then tightening it until it is held
tightly.
Cut the end of the pipe cleanly and squarely by using a pipe cutter. The pipe cutter will have a thin
cutter wheel, which will slice through the pipe as you guide it in the space. Be sure to wear goggles and
protective gear.
Ream the cut end of the pipe to remove any burrs from the cut using a reamer, which is a cylinder-
shaped rotary cutting tool that runs smoothly across the freshly cut edges of the pipe to remove rough
edges.
Select the die head according to the size and type of pipe that is being threaded.
Place the die head over the pipe on the threader.
Press steadily on the front of the die head, while simultaneously pushing the handle down to start the
threader. Before placing too much pressure on the handle, check to be sure that the ratchet pawl is
engaged.
Use weight as leverage to apply pressure on the handle, while holding it firmly. Be sure to maintain
proper footing and balance for maximum control. Never use a tool or mechanism to hold the handle in
place in order to free your hands, this can be dangerous and could result in injury.
Apply threading oil generously while threading. Using oil too thin as a substitute for threading oil can
result in sub-standard threading.
Cease threading when the end of the threading die is flat against the end of the pipe. When the die is
even with the pipe, that means the correct threading size has been reached. If you continue pushing
after this point, you will damage the thread.
Reverse the ratchet mechanism and turn the die head in the opposite direction. Be care full to maintain
control of the threader as the dies are removed. Threads can be damaged when the die head is being
removed if you don’t maintain control and move the piece smoothly.
Stand the pipe on end and gently tap it to remove any particles that may be lodged within.
Clean the pipe with cloth, removing any oil. Be careful, the threads will be very sharp.
Seal the threading with a pipe thread compound when attaching the pipe to the connector.
Clean the pipe threader machine thoroughly after use so the oils and metal pieces do not damage the
machine, which could cause sub-standard threading during your next project.
11. CONSTRUCTION METHOD FOR STANDPIPES AND SPRINKLER PIPES
The mechanical supervisor will instruct tradesmen regarding the execution of the works and will
distribute all necessary approved shop drawings of the latest version. The supervisor will also check that
the tools and equipment available are in compliance with the contract requirements.
After marking the pipe routes, the anchoring points will be drilled according to the required support
spacing as shown on the approved shop drawings.
Approved type of pipe support/ Hanger will be attached to the threaded rods, nuts, and washers will be
installed as well.
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 745 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
Piping shall be supported with approved clevis hangers and rods.
Pipes will be free from burrs, rust, scale, and other defects and will be thoroughly cleaned.
The branch lines will be hanged to the proper level and will be connected to the cross main.
Pipe slope shall be properly pitched down while installation of pipework to facilitate drainage of the
piping system.
Hangers shall be adequate to maintain alignment and to prevent sagging of the pipe.
Rigid support shall be provided near the zone control valve of the sprinkler and firefighting system.
Sleeves/ openings of suitable sizes will be provided at wall crossings.
Supports will be fixed in place by an approved construction method to suit the elevation of the piping as
indicated and the approved shop drawings.
Pipework will rest freely on supports and carefully aligned prior to final connection to each other, or any
other pertaining equipment as listed in the scope of works.
Where pipes enter through openings in fire-rated walls, an approved fire-stop will be used for sealing of
opening.
Pipeworks will be assured against damage from earthquakes by means of flexible and rigid couplings,
sway bracing, seismic separation assemblies where piping crosses building seismic separation joints.
Anchors, expansion joints, swing joints, and/or expansion loops shall be provided so that piping may
expand and contract without damage to itself, equipment, or the building.
Flexible couplings shall be installed at locations where piping crosses building expansion joints.
A test & drain valve shall be installed in the zone control valve station on each floor.
12. INSTALLATIONS OF RISER PIPES
Additional anchoring support and flexible coupling shall be provided in risers at a suitable location to
accommodate the expansion or as per the approved drawing.
Vertical pipework will be supported by riser clamps and fixed points secured to the piping at the base of
every level and as indicated on the approved construction drawings
Temporary caps will be provided to all open ends of the pipe upon completing the work in a day.
Sleeves shall be provided in all penetration through slab and walls.
Automatic Air vents and drain points shall be provided in the pipe at high and low points respectively.
Once the riser is erected, the pipe shall be offered for inspection and leakage test.
HANGERS AND SUPPORTS SPACING
Space pipe hangers and supports for carbon steel pipe in accordance with the specifications.
Hangers spacing shall be such that the piping is installed without undue strains and stresses and provision
shall be made for expansion, contraction, structural settlement, and water-hammer.
Nominal Outside Dia. ln. (ND) Pipe Size Actual Outside Dia. ln. (mm) Pipe Size Water Service Feet (meters)
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MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
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1 (25) 1.315 (33.7) 12 (3,7)
1.25 (32) 1.660 (42.4) (3,7)
1.5 (40) 1.900 (48.3) 15 (4.6)
2.5 (65) 2.875 (73.0) 15 (4.6)
3 (80) 3.500 (88.9) 15 (4.6)
4 (100) 4.500 (114.3) 15 (4.6)
6 (150) 6.625 (168.3) 15 (4.6)
8 (200) 8.625 (219.1) 15 (4.6)
Suggested Maximum Span Between Supports (Spacing corresponds to NFPA 13 Fire Sprinkler Systems)
The detailed spacing calculation and support details for the hollow core area will be mentioned in the
approved drawings.
13. SPRINKLER HEAD INSTALLATIONS
The pendant & upright sprinklers shall be arranged such that there is no interference with the discharge
pattern they shall be positioned between 25 and 300 mm below the ceiling.
The sprinklers and pipelines shall not be too close together in order to prevent an operating sprinkler
from wetting and thereby delaying the operation of adjacent sprinklers.
In locations where sprinklers’ heads are liable to be operated or damaged by accidental blow, they
should be protected by stout metal guards. Care shall be taken to ensure that the normal operation of
the sprinkler head in the event of a fire is not impeded by such guards.
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The distance between sprinklers shall not exceed 3.5 m. the maximum floor area to be covered by a
single sprinkler for different hazards are as follows:
• Light hazard =21 m2
• Ordinary hazard =12 m2
• Extra hazard =9 m2
The distance from the walls to the end sprinkler branch lines shall not exceed half of the allowable
distance between sprinklers on the branch line. The distance from the walls to the end branch lines shall
not exceed half of the allowable distance between the branch lines.
Ensure the sidewall sprinklers are installed only at light hazards and ordinary hazard occupancies with
smooth, horizontal, or sloped flat ceilings.
Prior to installation of the horizontal sidewall, sprinklers verify that the face of the sprinkler fitting is
within the proper range of distance, which can be accommodated by the type of escutcheon being used.
The horizontal sidewall sprinklers must be installed on the centerline of the waterway horizontal and
perpendicular to the back wall surface .it is recommended that a lightweight spirit level, be used to level
the sprinkler fitting and a square should be used to check the perpendicularity of the waterway
centerline to the mounting surface.
With pipe thread sealant applied to the pipe threads and after installing standard escutcheon, over the
sprinkler thread, hand tightens the sprinkler into the sprinkler fitting.
Ensure an adequate quantity of additional sprinkler heads of correct temperature rating is provided.
For systems not exceeding 300 sprinklers,6 spare heads shall be installed.
For systems exceeding 300 sprinklers but not exceeding 1000, 12 spare heads shall be installed.
For systems exceeding 1000 sprinklers, 24 spare heads shall be installed.
14. PRESSURE TESTING AND PROCEDURE
Carry out all tests and inspections to prove that the installation meets the requirements of the NFPA 13,
NFPA14, NFPA 20, NFPA 22, and NFPA 25 guidance.
Make available a highlighted drawing of the area intended for hydrostatic pressure testing.
Indicate on the drawing the location of vent/drain valve, plugged connections, and water pressure pump
connections.
Place safety warnings at all points where personnel may pass through within the vicinity of testing.
Attach the pressure pump to the desired location through an isolation valve, bypass valve, and calibrated
pressure gauge to indicate the pressure on the pipework.
The drain point will be plugged and the highest point of the system will be considered as the water
supply point for pressure testing. The selected supply point will be provided with an isolation valve,
calibrated pressure gauge, and manual water pump.
Isolate any parts of the system whose pressure rating is less than the testing pressure such as relief
valves, automatic air vents, and all devices that might be damaged by the test pressure.
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No pressure shall be applied against the closed gate of gate valves. All valves shall be in the open position
but completely back seated during testing. End valves shall be capped installed by a blind flange.
No testing shall be carried out against or through the pressure reducing valves. The setting of the
pressure reducing valves shall not be changed for testing purposes.
Plug all the open ends of pipes, keeping only two points open, one at the highest end & the other at the
lowest end of the pipe section to be checked.
Verify pressure gauges for calibration certificates. Check the proper filling and pressurization sequence of
the piping system to be tested.
Fill the pipe slowly with water through the filling point. Do not use a power-driven pump unless
approved.
Fill absorbent pipes with water and allow them to stand 15 mins at working pressure.
Once all the air in the pipe system is purged through the “purge point” and only water starts flowing out
indicating that the pipeline is free from trapped air, shut the air relief gate valve at the top end of the
pipeline. Once the pipeline is filled with water shut the gate valve at the filling point too.
Now start applying water pressure through a hydraulic pressure pump, till the pipeline attains a test
pressure of 1.5 times the working pressure for 2 hours. ( Working Pressure is 160 psi x 1.5 = 240 psi or
16.54 bar. i.e. The testing Pressure.)
Walk along the pipeline route & Inspect for any leakage. If any leakage is found, drain off the water from
the system by opening the filling point at the lowest end of the system. Rectify the leak by tightening the
joint or replacing of defective pipe I fitting as the case may be.
The test pressure shall be read from a gauge located at the low elevation point of the system or portion
being tested.
Once the test has been satisfactorily completed the test pressure shall be released slowly so as not to
produce shocks and sudden contractions that might damage the piping.
The system then shall be drained and the QC coordinator shall be notified.
A pressure testing report shall be prepared and signed by the client or any other concerned party.
Protect the piping installation and end cap the pipe.
15. WORKING IN DOUBLE HEIGHT AREA TO INSTALL THE SPRINKLER PIPES
GENERAL
In the drive area, HVAC ducts are installed, and don’t have access to reach the roof to install the sprinkler
pipes. (mostly branch pipes)
a) For example consider the double-height area, ducts were already installed main pipes and workers
cannot access the roof to install branch pipes and main sprinkler pipes. In this special case, we need to
stand on the duct or erect
scaffolding to complete the works.
Two methods can follow to install the sprinkler pipes.
Using duct as a platform so people can stand on the duct by using lifeline and complete the work.
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Using the scaffolding to install the pipes.
Please note, both methods will be followed on-site, the requirement will be as per site condition.
Option 1-Using Duct as Platform
Working at height should comply with project specifications.
Before starting the works, people should complete the formal training about working at height.
Here is a special case, that needs to work above the duct. This method will be followed only if scaffolding
cannot be erected.
Use the same channel used to lift the duct which is not removed.
If that temporary plate or channel is not available then fabricate Plate and U clamp will be fabricated.
The channel will be anchored in the soffit ( existing precast roof).
By using the scissor lift/ scaffolding plumbers, helpers need to climb on the duct.
Before standing on the duct, make sure a proper lifeline is provided.
People should wear lifelines and tie them in the anchor points.
The pull-out test is already completed for the fischer anchor so workers can use it as an anchorage point.
Make sure lifeline enough length to place mobilize.
Now place a wooden board above the duct – the purpose of the wooden board is people should stand on
the wooden board to avoid damage to duct insulation.
Place the wooden board on the duct flange to avoid damage.
Workers can climb on the duct using a scissor lift and stand on the wooden board.
Now plumbers/ workers can start doing the installation works.
Workers should not keep any sharp materials above the duct to avoid insulation damage.
Make sure fall arrest is enough length so workers can walk safely.
Until complete the works, the spotter should stand in a scissor lift for emergency and monitor the works.
Safety needs to monitor the works regularly.
The area needs to be barricaded until the completion of works.
Place warning sign- “PEOPLE ARE WORKING IN TOP”
Make sure illumination is available to complete the task.
Now start the installation of pipes.
The permit needs to be obtained from the main contractor safety.
Option 2-Working on a Scaffolding
This method can be followed if space is enough to place a scaffolding.
Erect a scaffolding in the working area in the double-height area.
Make sure the safety officer has inspected the scaffolding and certified it.
Now people should stand on the scaffolding and start the works.
Tie the lifeline in the existing anchor points ( as mentioned in Option 1)
Now start the installation of pipes.
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16. COMPETENCE AND COMPLIANCE
The Method Statement for Standpipes, Sprinkler Pipes, and Accessories Installations provided shall
include a detailed clause-wise compliance statement in respect of:
REGULATORY COMPLIANCE
This method statement has been developed to follow the regulatory requirements and as per project
specifications.
COMPETENCY OF AUTHOR/ORIGINATOR
This method statement includes a statement verifying the competence of the document author/
originator and demonstrating competency.
CONSTRUCTION/INSTALLATION (SADD’S)
The project specifications compliance requirements section reference documents SADD’s are deemed to
be a condition of this Method Statement for Standpipes, Sprinkler Pipes, and Accessories
Installations are provided to demonstrate that the procedures identified are actually adhered at the site.
17. RISK ASSESSMENT, HEALTH AND SAFETY COMPLIANCE
This method statement has been developed specifically for the works specified in the designated area. A
Risk Assessment of this work has been undertaken by the approved safety manager as per requirement.
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Page 751 of 864
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METHOD STATEMENT FOR
STORM DRAINAGE
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Page 752 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
SR. EFFECTIVE REV. MSS MANAGER MSS PROJECT CLIENT
CLIENT QA/QC
NO. DATE NO. QA/QC MANAGER SUPERVISOR
STORM DRAINAGE
This Method Statement of Storm Drainage (Installation and Testing) defines the requirements for
installation and testing of vitrified clay pipes and fittings for the storm drainage system. Moreover, this
provides guidelines to check that specified materials are installed and as per quality procedures, health,
safety & environmental (HSE) standards are implemented during the execution of work. The
specifications, procedures, and guidelines contained in this method statement specify the technical
requirements to be followed and also act as a reference to clearly establish standards for work
assessment.
1. TRANSPORTATION, HANDLING, AND STORAGE
All materials shall be handled/transported/stored in an optimal way that will not cause
damage to them.
The material will be delivered at the site in undamaged condition, in manufacturer’s packaging,
with identifying labels intact and legible.
Pipes are to be checked on unloading. Possible damages are reported on the delivery note.
Timbers and packing shall be provided by the contractor, necessary for the correct stacking of
pipes, fittings, and other delivered materials.
Pipes or fittings will not be drop or drag.
Pipes and fittings will be offloaded in our laydown area prior to transport to the site.
The storage area must be flat. The ground must not be marshy or unstable.
Timber supports of suitable size shall be placed at an equal distance below the vitrified clay
pipes.
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Pallets are loaded/unloaded only by convenient equipment (i.e. a forklift) which do not
allow any damages to pipes and fittings.
Dropping, lifting, or lowering pipes with jerking movements or suddenly letting them to the
ground will cause damages. In case of other lifting machines (i.e. Cranes) is used for loading/unloading,
wooden bars must be laid between the slings to ensure that no damages occur to the pipes
Pipes shall be handled special care during transportation/loading in order to protect from accidental
damage. Use hooks with special protection of plastic or rubber to avoid damage to the exterior of the
pipe.
The layer of pipe stacks will be in accordance with the manufacturer’s storage and handling
recommendations.
Do not move the pallets on the truck with the aid of levers or crowbars.
Put the pallets down only on the ground that is sufficiently hard to prevent the base timber from sinking
into it.
Leave sufficient space between individual pallets.
The storage area shall be cleaned and is at an appropriate height from the ground level. The materials shall
be stored in a shaded area to protect them from exposure to direct sunlight/rain etc. Separate areas in
the storage zone must be marked for different materials.
Whenever heavy or bulky material is to be moved, the material handling needs will be evaluated in terms of
weight, size, distance, and path of movement.
Never transport individual pipes in the excavator shovel.
Dragging or rolling pipes is not allowed. Packs or individual pipes should be set down on a reasonable
leveled surface and off the ground by a square timber to protect the “K” joint of the spigot end from the
damage.
Pipes shall be stacked on a flat surface free from any sharp objects and shall be given adequate supports at
all times. Put down the parcel on flat ground so that the pipes do not slip when the securing bands are
cut.
Damaged and defective pipes shall not be used at the site. The pipe shall be re-inspected just prior to
installation. Pipe shipping, storage, and handling shall comply with the manufacturer method statement.
2. MATERIAL INSPECTION
For materials to be inspected (as per approved material submittal after receiving at the site, the following
points are to be followed:
Each material item shall be allotted a distinct and separate reference number and mentioned on the
material requisition. Make sure that material is approved/examined by the Consultant and QAQC and
associated documents/test certificates are approved.
The Store In-charge shall ensure that all approved supplies be delivered to the site as per the approved
material submittal; with the manufacturer’s seals, labels, or other proof of origin intact. These labels
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and seals shall not be removed until the material is required for use and shall be retained for
inspection by the Consultant and QA/QC.
Store In-charge shall initiate material inspection for all incoming material to QA/QC and the material
shall be inspected against reference documents and as per approved material submittal. Moreover,
the physical condition of the material shall be checked. Afterward, an IR (Inspection Request) shall be
raised by QA/QC to the Consultant and inspection will be carried out by the Consultant.
Materials, which do not conform to the given specification/approved material submittal, shall be
rejected. Any discrepancies or damages will be notified and reported for further action.
For any materials inspection (especially pipes, fittings, other accessories), the items shall be segregated
as per their type/sizes and placed items separately in racks or on different pallets.
Each rack/pallet shall have an identification posted on laminated paper with the description of the items
clearly written on it.
There shall be appropriate spaces between the pallets so that the engineer/inspector can freely go
around them and inspect the materials thoroughly.
Staking the materials all over each other & in one corner is strictly not allowed.
All items shall be kept in a protective environment and shall not be kept directly on the floor; they shall
have wooden pallets underneath them.
3. METHODOLOGY
4. PRE INSTALLATION
1. All necessary work permits shall be obtained prior to the commencement of any activity at the site and
shall remain valid throughout the entire duration of the operation.
2. Site interface permits to be taken from other contractors before placing pipe at tie-in point to reconfirm
invert level and coordinates.
3. All activities for surveying, earthwork, trench excavation, pipe bedding in trenches, initial backfilling and
final backfilling, laying of marker tapes, and all associated jobs relate to Civil shall be done by Civil
Contractor.
4. Dewatering shall be added if the excavation level is lower than the water table. Dewatering shall be
performed by Civil Contractor.
5. Check & verify that the civil work is completed in compliance with all requirements for installation as per
approved shop drawing and handed over for mechanical works. Joint inspection of the location shall be
carried out by Consultant & Contractor before releasing the excavated trench for installation works.
6. For water-logged area, Gabbro material as gravel shall be used.
7. Prior to the commencement of work, inspect areas and access to confirm that the site is ready to
commence the work and coordinate with other trades and subcontractors.
8. Ensure that proper and dry trench beddings are placed.
9. Ensure that gridlines, reference levels, etc. are marked.
10. Ensure trenches are free from obstruction, rocks, and other debris prior to laying pipes.
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11. All relevant documentation approved shop drawings, and material applicable to a particular section of
works will be checked by Site Engineer prior to commencement of work.
12. Ensure that Material received is in compliance with the Project Specifications/Authorities Regulations
and is approved.
13. Ensure that all required materials and accessories are delivered, inspected, and approved by the
Consultant and are readily available at the site to carry out the work.
14. The site Engineer and his Supervisor/Foremen will carry out a site survey and mark the route of piping as
per approved shop drawings. In the event of any discrepancies or difficulties in executing the work, these
shall be brought to the notice by the Construction Manager for corrective action.
15. All relevant documentation (includes MST and RA are approved, obtain necessary work permits, fill up
STARRT cards after completion of daily toolbox talk), will be checked by Site Engineer prior to
commencement of work.
16. The Site Engineer/Site Supervisor will give necessary instructions to tradesmen (Plumbers/pipe installers)
and provide necessary approved construction/shop drawings.
17. The Site Engineer/Site Foreman will check that proper tools and equipment are available to carry out the
work and are in compliance with contract specifications.
18. The Site Engineer will explain to his team about HSE precautions to be observed.
5. INSTALLATION STEPS:
PIPE CUTTING/FABRICATION
1. Visually check the condition of pipe i.e. Crack, straightness, and rust.
2. If the required length is not standard, pipe cutting shall be performed. Preferably cutting of pipe should
be avoided at the site.
3. Pipes up to 450 mm in diameter shall be cut by chain cutter. Pipes 150 mm and 100 mm in diameter shall
be cut by using a cutting ring.
4. Measure the required pipe length and mark it for the cut.
5. Adjust the chain at the required length of the pipe for cutting.
6. Tight the chain around the pipe and buckle it up with the arm of the cutter and fold back the surplus
chain.
7. Tighten up the chain by turning the horizontal handle till the pipe is cut.
6. LAYING OF PIPES IN TRENCH BEDDING
All Civil related works are mentioned here for reference only. Civil works shall be performed by Civil
Contractor.
The laying of drainage pipes in trenches shall be in accordance with the relevant provisions of project
specification/manufacturer’s recommendations.
7. GENERAL
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NAME:
1. Vitrified clay pipes shall be installed in trenches that shall not exceed the maximum trench width at
300 mm above the crown of the pipe as shown in Table 2.1.
2. Pipe bedding shall be provided as shown on the Drawings or stated in the Contractor’s approved
methods statement.
3. Pipe bedding shall be well compacted and shall completely fill the whole width of the trench
excavated.
Maximum Trench Maximum Trench
Nominal Bore mm Nominal Bore
Width mm Width mm
100 550 600 1350
150 600 800 1550
200 800 1000 2000
300 900 1200 2300
400 1000 1400 2500
500 1250 1500 2700
Granular bedding material for rigid pipes shall conform with the following requirements:
Shall be clean gravel or broken stone from a source approved by the Engineer.
Gabbro shall be used in water-logged ground.
The granular material size shall be according to the following grading limits giving in Table 2.2.
Nominal Bore BS Sieve Size, 100% Passing By Weight-Dry BS Sieve Size, 100% Passing By Weight-Wet
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 757 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
mm Condition Condition
100 & 150 14 20
200 -500 29 37.5
600-800 37.5 50
1000 & above 37.5 50
Table 2.2
1. Bedding for pipes shall be constructed by spreading and compacting granular bedding material over the
whole width of the pipe trench.
2. Bedding material shall be in accordance with the project specifications.
3. Nominal single-sized aggregate and graded aggregate shall comply with Table No. 4 of BS 882.
4. Sand for bedding material shall comply with the relevant provisions of BS 882.
5. Bedding systems other than those specified in this clause may be allowed upon approval of the Engineer or
as recommended by the pipe manufacturer.
6. Unless otherwise specified, pipe bedding shall be as shown on the Contract Drawings.
7. Notwithstanding the above, for vitrified clay pipe, the special pipe bedding requirements as Table 4.2 are to
be provided in all cases whether or not shown on the drawings or indicated in the bills of quantity.
Nominal bore mm Depth to Invert (D) m Bedding Type
4.3.2.1.1 Plain concrete
700-800 D>9.0
cradle
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>900 4.0<D<5.0 4.3.2.1.2 Plain concrete cradle
Reinforce concrete cradle with
>900 5.0<D<9.0
minimum 0.4% transverse steel
Reinforced concrete surround with
>900 D>9.0
minimum of 1% transverse steel
Table 4.2
1. Where socketed pipes are required to be laid on a granular or sand bed, or directly on a trench bottom, joint
holes shall be formed in the bedding material or final excavated surface to ensure that each pipe is uniformly
supported throughout the length of its barrel and to enable the joint to make.
2. Pipes shall be laid on setting blocks only where a concrete bed or cradle is used and is required by approved
drawings and project specifications.
3. Where pipes are required to be bedded directly on the trench bottom, the final excavated surface shall be
trimmed and leveled to provide even bedding for the pipeline and shall be free from all extraneous matter
that may damage the pipe, pipe coating, or sleeving.
4. Where rock is encountered, the trench shall be cut at least 150 mm deeper than other ground and made up
with well compacted selected fill material.
5. No protective cap, disc, or other appliance on the end of a pipe or fitting shall be removed permanently until
the pipe or fitting which it protects is about to be jointed. Pipes and fittings, including any lining or sheathing,
shall be examined for damage and the joint surfaces and components shall be cleaned immediately before
laying.
6. Suitable measures shall be taken to prevent soil or other material from entering pipes and to anchor each
pipe to prevent flotation or other movements before the Works are complete.
7. Where pipeline marker tape is specified in approved drawings/specification, it shall be laid between 100 mm
and 300 mm above the pipe.
8. Marker tape shall be installed as per the project specifications. Its wording and color shall be in accordance
with the project requirement. For Foul water Red color tape.
8. PROTECTIVE COATINGS
Coatings, sheathings or wrappings shall be examined for damage, repaired where necessary, and made
continuous before trench excavations are backfilled.
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9. BACKFILLING
Backfilling shall, wherever practicable, be undertaken immediately the specified operations preceding it
have been completed. Backfilling shall not, however, be commenced until the parts of the works to be
covered have achieved a strength sufficient to withstand all loading imposed thereon.
1. Suitable material shall be used for backfilling. All required tests shall be performed prior to bedding
surround / backfilling.
2. Backfilling around existing structures shall be undertaken in such a manner as to avoid uneven loading or
damage.
3. Filling material to excavations shall be deposited in layers not exceeding 250 mm unconsolidated
thickness and compacted to 95% modified proctor.
4. Where the excavations have been supported and the supports are to be removed, these, where
practicable, shall be withdrawn progressively as backfilling proceeds in such a manner as to minimize the
danger of collapse. All voids formed behind the supports shall be carefully filled and compacted.
5. All safety measures shall be taken during excavation, bedding, compaction, and backfilling.
6. The open trench will be barricaded by warning tape. A warning sign shall be in place i.e. “Danger” “Deep
Excavation” “Keep Away” “Do Not Enter” “Work Under Progress” etc. Trench barricade requirement shall
not be limited to warning tape, adequate barricade to be provided to suit site conditions and area.
7. After completion of backfilling the pipe trench all warning signage, warning tape shall be removed and the
area will be cleaned.
8. Geotextile filter membrane shall be placed in the trench after formation level.
9. Concrete surround shall be provided around the pipe if the minimum cover depth is less than 1.2 m.
10. INSTALLATION PROCEDURE FOR UNDERGROUND PIPING
The laying/lowering of pipes shall be performed according to the project specifications, manufacturer’s
recommendations, and project specifications.
1. The trench will be made clear from any debris or any sharp object before laying the pipe in. The trench
bottom will be level to provide uniform bearing and support of pipes.
2. A trench survey will be done for ensuring the required pipe elevation as per approved drawings.
3. Lower the pipes and fittings into the trench with a crane or any suitable lifting / lowering machinery or
manually depending upon the weight, size, and length of the pipe. As per approved material and
specification, any external treatment or protection (sleeves, etc) are not applicable.
4. Wire rope or any metallic lifting sling will not be directly in contact with Vitrified Clay pipe while lifting or
lowering into the trench. Cotton Jute or soft rubber material will be wrapped to avoid damage to the pipe
at the place where the sling will tie for lifting the pipe. Care shall be taken to avoid damage of pipes during
lowering into the trench. Care should be taken in lowering the pipe into the trench to prevent damaging
the joint material or disturbing trench condition. Never allow the pipe to be damaged along the ground or
even at the trench bottom.
5. The pipe shall be laid in the upstream direction with the bell end laid upstream.
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6. Make/dig the pit (hole) in the soil under each pipe socket (Bell) for firmly resting pipe barrel on the trench
bottom or bedding material so that load is supported by the pipe barrel and not the pipe socket.
7. Join the pipe and fitting ensuring it invert elevation is as per the latest approved shop drawings. Please
refer section jointing procedure of this method statement.
8. For jointing methods, the manufacturer’s recommendation shall be followed where applicable.
9. Pipe passing through the concrete/wall shall be installed in sleeve. Sleeve material will be as per approved
material submittals. Pipe sleeve diameter to be 13 mm larger than the outside diameter of the pipe.
10. If required to prevent misalignment, underground piping shall be stabilized and secured as per approved
drawings or by thrust block at intervals, every branch, and every change of direction as specified in the
specification or drawings.
11. Protective caps shall be removed from pipes and fittings end prior to making joints and at every end of the
working day, pipes ends will be covered or will close with end caps.
12. After installation check for correct leveling, position, alignment, straightness, and required slope as per
International Plumbing Code.
13. Installation inspection will be offered for the part or complete portion of the entire underground piping.
Air Testing Inspection will be offered after approval of installation. Both inspections will be independent.
14. Piping will be backfilled and compacted as per project specifications. The minimum top coverage shall be
300 mm. This shall be in accordance with finalized specification document.
15. Clean the hub and spigot to be joined so they are free of all dirt, mud, sand, gravel, and other foreign
materials.
16. Remove sharp edges by filling or tapping with a ball-peen hammer.
17. By using a paintbrush apply the approved lubricant on both surfaces to be joined i.e. inside the socket end
and outside the spigot end. Lubricant to be stored as per manufacturer’s recommendations. Apply
lubricant to molding inside and on the spigot end (of K joint). Apply lubricant to lip ring and spigot end (of
L joint)
18. While applying lubricant care shall be taken to avoid contact with eyes or skin. The manufacturer’s safety
instruction shall be strictly followed.
19. Yellow marks printed at the external side of the pipes should be kept always at the crown.
20. Prepare trench bedding in the proper way and make sure it’s homogeneous, leveled, and dry.
21. Line up the socket and spigot and shave the pipes together with steady pressure, (for small diameters this
can be done by hand while for larger sizes, a crowbar may be used). Care should be taken not to damage
the lip of the socket by using a wooden block. The special device may be used for big diameters.
22. Laying pipes should be in the upstream direction with the bell end laid upstream.
23. Holes must be dug at each socket (bell hole) to make sure that the pipe barrel is resting firmly on the
trench bottom or bedding material so that load is supported by the pipe barrel and not the pipe socket.
24. Align (hub and spigot) yellow marks with other pipe yellow mark, then push spigot fully home into the
socket/hub with steady pressure.
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25. Make the joint of further pipes/fittings as procedure mentioned above.
11. TIPS FOR LAYING SEWER PIPES
Keep the trench width narrow, especially at the top of the pipe. A wide trench means more load on the
pipeline. Spread bedding material in front of the last pipe laid. Smooth it out.
Imported bedding should be at least 4 inches thick – thicker for the larger pipe. Make sure the bedding is
packed down.
Use a grade rod, laser, or grade machine to check the grade of bedding. This means less pipe handling
when the pipe is laid.
Dig bell or coupling holes before the pipe is laid. Just scoop out bedding with a shovel.
Keep water out of the trench so bedding can be placed and graded accurately. Pipe joints can be made
easier too.
Pump out water or use well points sunk below the depth of the trench bottom.
Follow manufacturer’s instructions for installation of flexible compression joints (where required).make
sure joints are clean before installing them.
If a bar is used to shove the pipe home, use a block of wood to cushion the bell. Make sure the pipe is
laid straight and to grade.
Tamp a layer of bedding material under the pipe haunches, not under the bell. This gives the pipe added
support and keeps it in line.
If too much bedding is thrown on top of the pipe, it would not get under the pipe even with tamping.
Don’t let this happen.
Make sure fittings, stubs and risers are well supported. Tamp the soil around and under haunches of the
pipe and fittings.
Use short stubs with flexible compression joints at manhole walls (if project specification/drawings
require). They will take care of the manhole settlements.
Hand covers the pipe with about 12 inches (30 cm) of backfill over the top of the pipe. This protects the
pipe during final backfilling.
Do not let the rocks or lumps get into the trench. They can damage the pipe and ruin the alignment.
Place final backfill into the trench at an angle. This keeps the impact on the installed pipe to a minimum.
Heavy compaction equipment should be used with caution. The pipe can be damaged if the impact is not
carefully controlled.
12. SWABBING/CLEANLINESS OF PIPELINES
1. Before testing, cleaning and swabbing of the pipeline shall be carried out.
2. Pipelines and manholes shall at all times be kept free of all silt, mortar, debris, and other obstructions.
When work is not in progress the open ends of the pipeline shall be securely plugged with an approved
watertight plug or stopper firmly fixed to resist unauthorized removal.
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3. The inside of each fitting and pipe length shall be cleared immediately before jointing and shall swab all
fittings and pipe lengths to remove all dirt, sand, or other matter that may clog the pipeline or
contaminate the fluid to be transported in the pipeline.
4. After jointing, the interior of the pipes shall be freed from any dirt, stones, or other matter that may have
entered them. For this purpose, a rubber disc, brush, or other suitable implements that will not harm the
internal lining of the pipe shall be pulled through the pipe after jointing.
13. TESTING
1. Testing a pipeline shall be carried out before any backfilling takes place and shall be repeated after
backfilling is completed, and should be in accordance with the standard specifications of water and air
testing of drain and sewers.
2. Each pipeline 600 mm or less in diameter shall be tested by air test. If any pipe fails the air test, the
Consultant /Engineer may order a water test to be carried out. Acceptance of the pipeline will then be
based on the results of the water test. All pipelines up to and including 1200 mm shall be tested by air
test in accordance with the requirements of BS EN 752.
3. Each pipeline shall be tested before backfilling and also after backfilling before carrying out road
reinstatement or laying new road surfacing. Where the pipeline is located under a new road alignment,
the pipeline will be tested after the sub-base compaction incomplete.
4. All pipelines shall be subjected to pass infiltration tests as specified herein. All pipes are to be clean and
empty at the time of testing. Tests shall be performed in the presence of the consultant/Engineer.
AIR TESTING OF A PIPELINE:
1. Prior to Air Testing, IR (Inspection Request) will be raised for approval of the installation of piping work.
2. Air testing of drainage will be carried out prior to closing / backfilling the trench.
3. Piping may be tested in sections or in total, depending on on-site requirements.
4. Trained Personnel will conduct the test monitored by a responsible site engineer and safety department.
5. Arrange for test plugs, 4″ (100 mm) U – tube manometer test kit with accessories.
6. Always coordinate with safety and construction departments for safe and methodical conduct of testing
works.
14. TESTING CRITERIA AND METHODOLOGY:
CRITERIA:
1. Installation Check – Piping layout, location, and size of pipe.
2. Air testing shall be in accordance with the project specifications.
3. Test Pressure-100 mm manometer (U – Tube) pressure.
4. Test duration-5 minutes.
5. Test Monitoring- pressure (in U tube – Manometer) should not fall below 3 inches (75mm) water gauge
in 5 minutes.
6. Pressure measurement/checking will be done in the U – tube manometer.
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Page 763 of 864
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STEPS:
1. Ensure that the pipes and fittings are capable of withstanding air leak tests.
2. Air testing can be applied to the system in its entirety or in sections. Once the above is checked and
found acceptable, proceed with the test.
3. Inspect pipeline for possible damage during or subsequent to laying.
4. Thoroughly check all plugs and equipment. The average drain plug is quite often not airtight and rubber
tubing used in connections must be in good condition and not perished.
5. Ensure that the ends of the line are adequately strutted against movement with all plugs held firmly in
position.
6. Pump or blow in the air until a pressure of slightly in excess of 4 inches (100mm) water gauge is indicated
on the manometer connected to the system. Pumping or blowing warms the air so a minute or two
should be allowed for this to cool to the pipe temperature.
7. If necessary, then reduce the pressure to 4 inches (100mm) water gauge. During a further period of 5
minutes, the air pressure should not fall below 3 inches (75mm) water gauge.
8. The Testing team will conduct a soap test at the joints if an air leak is identified.
9. If any leaks are detected then they are to be attended to prior to proceeding further.
10. Repeat the procedure after attending to the leaks (if any).
11. Once it is confirmed that there is no leak in the system and maintain pressure in the piping for 5 minutes.
12. Inspection Request (IR) will be raised for the client/ consultant to witness the Air Test. The local authority
does not require witness the test.
13. After consultant inspection, the system will be vented until normal pressure is attained.
15. PROCEDURES FOR HANDLING AIR TEST FAILURE
BEFORE BACKFILL
a) Readjust the pipe pressure to the specified test pressure and examine for leakage by pouring a
solution of soft soap and water over the exposed joints if the test fails.
b) Repair leaks and repeat testing where leaks are found at joints.
c) Where leaks are not found at joints, move the plug, the one that is not used to exert air pressure,
along the pipeline to isolate lengths with leakage. Uncover pipe barrels in the isolated lengths where
leakage in pipe barrels is suspected. Replace leaking pipe lengths and repeat testing.
d) Conduct low-pressure water testing to verify that the air test was not erroneous where the test
length fails the air test but no source of leakage can be identified. Consultant’s consent is required
as per site conditions.
AFTER BACKFILLING
a)Move the plug up from the other end along the sewer pipeline to isolate the lengths that fail the
air test.
b) Exhume the failed length of the pipeline and replace pipe lengths.
c) Repeat the air test.
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d) Conduct water testing to check that the air test was not erroneous when failed lengths could not
be isolated using the air test. Consultant’s consent is required as per site conditions.
e) Use CCTV or a suitable recording medium, when required or available, to identify the leakage if the
failed section cannot be isolated by the air test or water test.
16. WATER TESTING OF A PIPELINE:
(Shall be done after consultant’s approval where Air Test failed)
PREPARATION
Before testing, attention should be paid to the following points:
1. Inspect pipeline for possible damage during or subsequent to laying.
2. Plugs, should be thoroughly checked. Faulty plugs will invalidate test results.
3. Close all openings in the line with watertight seals (Test Stoppers) ensuring against
movement. i.e. all plugs held firmly in position.
4. Ventilating valve should be fixed at the high point of the section.
PROCEDURE:
1. All the joints of the pipeline shall be able to withstand a pressure of a minimum of 5 m head of water,
above the crown of pipe at the highest point of the pipeline without leakage. A layer of embedding soil
equal to the diameter of the pipe shall be laid over the pipe to prevent the lifting of the pipe while
applying test pressure. However, all the joints shall be left open for the purpose of inspection for leakage
if any. All branches and open ends shall be closed with stoppers, secured with longitudinal braces/thrust
block before testing begins.
2. Water shall be filled from the lowest point and air allowed to escape through an air vent fixed for the
purpose at the high points of the pipeline section under test. The diameter of the air vent shall be about
one and half times the diameter of the water inlet pipe to allow easy escape of air. No entrapped air shall
remain in the pipeline while testing.
3. A pressure of 5 m head of water shall be maintained for one hour to allow initial absorption of water.
After that, the test pressure shall be maintained for 15 min and water added shall be measured. If water
consumption in 15 min does not exceed 0.1 l/m2 of wetted inner pipe surface and if there is no visible
leakage through joints, the pipeline shall be treated as passed.
INFILTRATION TESTING A PIPELINE:
GENERAL
1. This test method defines procedures for hydrostatic infiltration testing of new installations of vitrified
clay pipelines, to demonstrate the structural integrity of the installed line as per ASTM C 1091 – 03a.
2. This test method is suitable for testing gravity-flow pipelines constructed of vitrified clay pipes or
combinations of clay pipes and other pipe materials.
3. This test method is applicable to the testing of the pipelines only.
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4. The upper ends of the sewer and service connections shall be closed sufficiently to prevent the entry of
water and pumping of groundwater shall be discontinued until the groundwater-surface reaches its
natural level before beginning the infiltration test.
5. The dewatering system shall be stopped, but not be removed until the infiltration test has been
successfully completed or as otherwise permitted by the Consultant/Engineer.
PROCEDURE
1. The hydrostatic infiltration test procedure is applicable where the measured water table is 2 ft (610 mm)
or greater above the pipe barrel at the lower manhole of the test section. Where the groundwater
elevation is indeterminate, less than 2 ft (610 mm) above the top of the pipe barrel, or the line is partially
below the water table, use a combination of both the air test and infiltration procedure.
2. Note 1-The most practical method for testing is Air Test Method and is recommended.
3. However, where groundwater is present and meets the criteria established in this procedure, the
infiltration test procedure outlined in this practice is recommended.
4. Note 2- What can be called false infiltration represents condensate on the pipe walls.
5. The infiltration shall not exceed 6 liters per mm diameter per kilometer per day of the portion of a sewer
being tested, including the length of service connection entering that section.
6. The total length tested in one section shall not exceed 400 m in length. This length is dependent upon
the type of deflection measuring equipment proposed by the Contractor if flexible pipes are used.
7. No gravity pipeline will be accepted if the total infiltration exceeds the above-mentioned limit and joints
will not be accepted if, during an internal inspection, any infiltration is visible.
8. If the test section includes more than one pipe size, calculate the allowable test rate for each size and
add to arrive at the total allowable test rate for the test section.
9. External drainage pipelines shall be tested for infiltration after backfilling. All inlets to the system shall be
effectively closed, and any residual flow shall be deemed to be infiltration.
10. The pipeline shall be accepted as satisfactory if the infiltration, including infiltration into manholes, in 30
minutes does not exceed 0.5 liters per linear meter per meter of the nominal bore. This relationship in
equation format, with water infiltration measured in liters, can be written as follows: Maximum volume
of infiltration over a 30 minute period = 0.5 x L x D Where: L = pipe diameter (m) D = Length of test
section (m)
17 .CCTV SURVEY
1. CCTV survey shall be carried out on a representative sample of no more than 12% of the length of
constructed pipelines if the ConsultanUEngineer’s Representative requires.
2. In case this survey indicates sections of the pipeline fail to meet the specification requirements,
undertake additional CCTV after remedial works will be carried out.
SETTING-UP OF EQUIPMENT
1. Place visible signage i.e. “System Under Pressure”, “Keep Away”, “Danger”, “Caution”.
2. Warning notices and barricades (if deemed necessary) will be used to identify the system under test.
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Page 766 of 864
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CLEAN-UP AND RESTORATION
1. After a successful test, remove carefully all temporary plugs.
2. Remove warning signage and temporary barricades in a safe and orderly manner such that the work area
is restored as is prior to conducting the test.
3. Clean the work area thoroughly prior to transfer to another test location.
18. HEALTH, SAFETY AND ENVIRONMENT -METHOD STATEMENT OF STORM DRAINAGE SYSTEM
A. HSE Risk Assessment
B. Permit and Licensing Requirements
The required permit to work shall be obtained prior to the commencement of work. This shall be
coordinated with HSE. Site interface permits to be taken from other contractors before placing
pipe at tie-in point to reconfirm IL and coordinates.
C. Pre-Start Safety Briefing Arrangements
C.1 Protective and Safety Equipment
All workers Involved shall be equipped with adequate PPE as stated below:
1. Safety Helmet with Company Logo
2. Safety Boots
3. High Visibility Vest
4. Safety Goggles
5. Hand Gloves
6. Coveralls
7. Proper safety harness
C.2 Information to Personnel
1. Safety Induction
2. Job training
All the personnel involved in this task shall be provided training and only trained
personnel shall be authorized to work around this area.
Toolbox talks
STARRT Card
C.3 Special Safety Requirements:
1. All necessary personal/protective equipment (PPE), as well as harness, be provided.
2. Rigging Team, wearing distinctive vests, shall be assigned to help operators maneuver their equipment.
3. The equipment operators shall possess the required licenses and certificates.
4. The required permit to work shall be obtained prior to the commencement of work.
5. The project safety officer is responsible along with the project zone site engineer for ensuring that all
operations are carried out with due regard to the safety of all project personnel & property.
6. Working at height to be monitored with due care.
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
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DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 767 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
7. The contractor must provide a safe place of works, with safe access and egress. Provide a safe working
environment that is without risk to health.
19. QUALITY ASSURANCE AND QUALITY CONTROL-METHOD STATEMENT OF STORM DRAINAGE SYSTEM
A. Quality Assurance Requirements
The contractor shall provide the required documents for the Consultant’s approval prior to initiate
with the execution of this activity as per project specification requirements.
The Quality Control requirement shall include related ITP’s and other related documents
as applicable.
B. Quality Assurance Process
The contractor shall notify the Engineer 24 hours in advance prior to the start of activity and
Comments from the Site Instruction will comply with the satisfaction of the consultant.
The contractor shall consult the public utility authorities not less than one month before it is
proposed to commence work to ascertain whether any underground installations will be
affected by the proposed work, in which event the contractor shall make all necessary
arrangements with the public utility authorities to safeguard the installation.
C. Follow up and Evaluation
Follow up on quality performance shall be carried out through an in-house monitoring system
such as progress reporting to the planning department, daily, weekly, and monthly reports
generated by the planning department to closely monitor site performance.
All the above shall be conducted in close coordination with the quality department to
monitor any deviations from the Quality Management System requirement and induce
corrective actions whenever required to eliminate non-conformance or quality deviations.
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Page 768 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
METHOD STATEMENT FOR
INSTALLATION OF ELECTRICAL
CONDUITS & BOXES
SR. EFFECTIVE REV. MSS MANAGER MSS PROJECT CLIENT
CLIENT QA/QC
NO. DATE NO. QA/QC MANAGER SUPERVISOR
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Page 769 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
INSTALLATION OF ELECTRICAL CONDUITS & BOXES
1. PURPOSE
The method statement of electrical conduits and boxes installation describes the requirements to be
followed from the project specifications, quality procedures, and health, safety & environmental
standards which establish the defined guidelines for electrical work assessment and responsibilities.
Moreover, this document provides guidelines to check that specified materials are installed and agreed
procedures are implemented during the execution of work.
2. ELECTRICAL SYSTEM DESCRIPTION
Conduit system shall be used for embedded and exposed conduit system requirements:
Light and power circuits, fire alarm, telephone, signal, low current, and extra-low current system wiring
shall be drawn in conduits unless otherwise indicated.
Cable insulated for two different categories of circuits shall be segregated.
Irrespective of service, conduit and fitting used shall be:
Heavy gauge rigid PVC for embedded service.
Galvanized steel conduit for surface mounted exposed service.
Galvanized steel conduit throughout the circuit, for above false ceilings and in voids.
Galvanized steel conduit for flameproof and hazardous areas.
Flexible steel conduit for the terminal box to machine routes.
3. REFERENCES
Project Electrical Specification
Regulations for the installation of electrical wiring, electrical equipment
BS 4607 Non-metallic conduits & fittings for electrical installations rigid PVC conduits
BS 4568 Steel conduits and fittings
Approved material submittals
Approved shop drawings
4. ABBREVIATIONS
HSE Health Safety and Environment
QA/QC Quality Assurance and Quality Control
MST Method Statement
RSK Risk Assessment
ITP Inspection and Test Plan
PQP Project Quality Plan
INR Inspection Request
PPE Personnel Protective Equipment
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Page 770 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
MEP Mechanical, Electrical & Plumbing
STARRT Safety Task Analysis Risk Reduction Talk
5. THE PROCEDURE OF THE METHOD STATEMENT FOR ELECTRICAL CONDUITS AND BOXES INSTALLATION
A. PRE-INSTALLATION
a. All relevant documentation, approved shop drawings and material applicable to particular section of
works will be checked by Site Engineer prior to commencement of work.
b. Ensure that the material received is in compliance with the project specifications and is approved.
c. Ensure that all required materials and accessories are delivered, inspected, and approved by the
Consultant and are readily available at the site to carry out the work.
d. Prior to the commencement of work, areas, and access will be inspected to confirm that site is ready to
commence the work and coordinated with the related civil contractors.
e. All relevant documentation (includes MST and RA are approved, obtain necessary work permits, fill up
STARRT cards after completion of daily tool box talk), approved shop drawings and material applicable to
particular section of works will be checked by Site Engineer prior to commencement of work. Section of
works will be checked by Site Engineer prior to commencement of work.
f. The Site Engineer/Site Supervisor will give necessary instructions to tradesmen/electrician and provide
necessary approved construction/shop drawings.
g. The Site Engineer/Site Foreman will check that proper tools and equipment are available to carry out
the work and are in compliance with contract specification.
h. The Site Engineer will explain his team about HSE precautions to be observed.
i. The Site Engineer/Foreman ensures the cleanliness of area.
B. INSTALLATION
Conduits and boxes shall be used for light and power circuits, fire alarm, telephone, signal, and other low
current system wiring shall be drawn in conduits unless otherwise indicated.
B.1 INSTALLATION OF RIGID PVC CONDUIT AND BOXES
Site Supervisor / Foremen will carry out a site survey and mark the route of the conduit as per approved
drawings.
Run conduit in square, symmetrical lines, parallel to or at right angles to walls and in accordance with
the accepted practice.
Conduit system shall be mechanically continuous and watertight after installation. All conduit system
shall be arranged wherever possible to be self-draining.
Conduit runs between draw-in positions shall conform to governing national regulations regarding
no. of bends and lengths of the straight run as specified.
Installation shall permit easy drawing in of cables.
Keep conduits at least 100 mm from pipes and other non-electrical services.
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Page 771 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
Where conduit runs are to be concealed in the structure or are to pass through floor slabs, the
Contractor shall be responsible for marking the accurate positions of all chases and holes on site. The
Contractor shall arrange the conduit routing to make maximum use of any preformed conduit holes and
slots provided in structural beams. Conduit installation on shear walls shall be kept to a minimum. All
routings necessary on shear walls shall be agreed with the Consultant/Engineer before work is put in
hand.
Install conduits so as not to interfere with ceiling inserts, lights or ventilation outlets.
Arrange supports to prevent misalignment during wiring installation.
Fasten conduit supports to building structure and surfaces as per specification.
Route conduit parallel and perpendicular to walls.
Maintain adequate clearance between conduit and piping.
Cut conduit square using saw or pipe cutter; de-burr cut ends.
Bring conduit to shoulder of fittings; fasten securely.
Join nonmetallic conduit using cement as recommended by manufacturer. Wipe nonmetallic conduit
dry and clean before joining. Apply full even coat of cement to entire area inserted in fitting. Allow joint
to cure for 20 minutes, minimum.
Use conduit hubs or sealing locknuts to fasten conduit to boxes and fittings.
Install no more than equivalent of two 90-degree bends between boxes. Use conduit bodies to make
sharp changes in direction, as around beams. Use hydraulic one-shot bender to fabricate and factory
elbows for bends in metal conduit larger than 2-inch (50-mm) size.
Avoid moisture traps; provide junction box with drain fitting at low points in conduit system.
Provide suitable fittings to accommodate expansion and deflection where conduit crosses seismic,
control and expansion joints.
Provide suitable pull string in each empty conduit except sleeves and nipples.
Use suitable caps to protect installed conduit against entrance of dirt and moisture.
Provide supports for fittings independently of any false ceiling for sunk and concealed conduit systems.
Size conduits, draw-in boxes and junction boxes in accordance with specification, approved drawings /
standards and regulations.
Swab whole of the conduit system to remove any loose matter or dirt before cables are pulled in.
Where conduits connect to switch boxes draw-in boxes and the like the conduits must have a machined
faced socket screwed on to the end which when tightened is flush with the outside of the box. The
conduit is then to be secured to the apparatus by means of a hexagon smooth bore brass bush screwed
from the inside of the apparatus into the conduit socket in order to make a sound and tight mechanical
joint.
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Page 772 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
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All horizontal runs shall be supported at no more than 900 mm. Vertical runs shall be supported at no
more than 1200 mm. Where directional changes occur support shall be provided at no more than 150
mm either side of the bend.
Hot bending shall be carried out on all non-metallic conduits. A bending spring of the correct size shall
be used in all cases. The heat source shall be provided by a hot air torch. When the conduit is in a
pliable state it shall be bent around a suitable former and held in position until the conduit has set. No
other method will be approved.
Couplers slip type bends and spouted fittings shall be made using semi-permanent mastic sealing
compounds. Expansion couplers shall be used in surface installations where straight runs exceed 8
meters.
Standard junction or adaptable boxes shall be provided at all junctions and at sharp changes of
direction in addition to any special positions where they are required on Site. Inspection couplers may
be used in long runs to facilitate drawing in cables.
Particular care must be taken to ensure that no water is allowed to enter conduit at any time and all
conduits shall be arranged with adequate ventilation and drainage where necessary as directed by the
Consultant/Engineer. Inaccessible junction boxes will not be allowed.
Only continuous lengths of buried conduit shall be installed between boxes, no joint boxes being
allowed in the floor screeds. Conduits crossing expansion joints shall be fitted with couplings of
approved manufacture.
The ends of conduits laid or set in formwork prior to concreting shall be temporarily sealed off with a
coupler and a plug.
Fixing to surfaces of walls shall be by means of spacer bar saddles securely fixed by screws. Where
conduits are concealed or laid in structural floors they shall be held in position with substantial fixings
of make and pattern to be approved by the Engineer.
Adaptable boxes shall be manufactured from PVC as previously detailed for conduit boxes and sized to
provide sufficient space factor.
Weatherproof boxes and accessories shall be used outdoors where agreed on Site by the
Consultant/Engineer or where indicated in this Specification or on the Drawings.
Conduit shall be installed such as to permit complete rewiring without the need to remove false ceiling
or carry out builders work.
No single conduit serving phase socket outlets lighting points and switches shall contain more than one
phase.
Wiring shall be carried out on the looping-in system and no joints other than at looping-in points will be
allowed.
Where the conduit system terminates at any equipment requiring a non-rigid connection a flexible
conduit shall be installed of the PVC or PVC sheathed metallic type fully watertight with purpose made
connection adapters.
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Page 773 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
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CONTRACTOR
NAME:
Each flexible connection shall include not less than 400mm length of flexible conduit and a separate
earth conductor shall be run within the conduit connected to the earth terminals in the equipment and
the fixed conduit run. The flexible conduit shall not be used as an earth continuity conductor.
For Runs in Reinforced Concrete Slab:
(a) Obtain approval for placing PVC conduits before pouring concrete
(b) Run conduits in concrete slabs parallel to main reinforcing steel
(c) Additional openings in finished slabs, where approved, shall be made by drilling, not by breaking
(d) Conduit boxes shall not be nailed to shuttering boards.
For Horizontal or Cross Runs:
To be avoided in partitions and side walls.
For surface-mounted conduit (including conduit installed above the false ceiling):
(a) Fix with distance spacing saddles to allow conduits to be taken directly into accessories without
bends or sets.
For concealed conduit
(a) Fix securely to prevent movement before casting of concrete and screeds, application of plaster
and the like
(b) Spacing of clips shall not be greater than as follows:
Conduit Size Spacing
up to 25 mm 600 mm
32-38 mm 900 mm
50 mm 1000
5. RIGID STEEL CONDUIT AND FITTINGS
RIGID STEEL CONDUIT
Support conduit using coated steel or malleable iron straps, lay-in adjustable hangers, clevis hangers, and
split hangers.
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Page 774 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
Group related conduits; support using conduit rack. Construct rack using steel channel; provide space on
each for 25 percent additional conduits.
Do not support conduit with wire or perforated pipe straps. Remove wire used for temporary supports.
Do not attach conduit to ceiling support wires.
Arrange conduit to maintain headroom and present neat appearance.
Route conduit installed above accessible ceilings parallel and perpendicular to walls.
Route the conduit in and under slab from point-to-point.
All metallic conduits shall comply with BS 4568 and of Class 4 rigid steel screwed type having an interior
and exterior zinc coating of uniform quality and appearance throughout all surfaces.
Conduits shall not be less than 20 mm diameter size and shall be complete with all necessary threaded
fittings, couplings, and connecting devices having galvanized equivalent finish.
Conduits and fittings shall be manufactured especially for electric wiring purposes. When manufactured
by a continuous weld process, weld heads both inside and outside the tube shall be completely removed
prior to galvanizing.
All conduits and fittings shall be free from rust or other defects on delivery to the site and shall be
properly stored in covered racking so that it is protected from mechanical damage and damage by
weather and water whilst stored on the site
All conduits shall be coupled to boxes and trunking wires using brass male bushes. All such bushes shall be
hexagon headed, heavy-duty long threaded type.
All conduit expansion couplings used shall be fabricated from material equal or equivalent to that of the
conduit with which the coupling is to be used, having factory-installed packing ring and pressure ring to
prevent entrance of moisture. All coupling shall be equipped with the earthing ring or earthing conductor.
All conduit runs shall be fixed using spacer bar pattern saddles giving not less than 3 mm clearance
between the conduit and the surface to which it is fixed. Saddles shall have a finish to match the conduit
and saddle clips shall be secured to the bar by means of brass screws.
METALLIC CONDUIT BOXES
Metallic conduit boxes shall be used throughout metallic conduit raceway systems, and shall comply with,
or be of demonstrated equivalent quality and performance to BS 4568 requirements. All boxes and covers
shall be galvanized, zinc plated or rust-proof finish equivalent to conduit finish
Circular and/or rectangular boxes shall be used for pull boxes and terminating boxes, according to size
and number of conduits connected to box. Boxes shall be either malleable iron or heavy duty steel
construction with welded joints and tapped holes to receive metal threaded cover retaining screws. Self-
tapping screws will not be permitted.
All boxes, other than those to which a fitting or accessory is to be directly mounted shall be fitted with
covers screwed to the box by brass screws. Malleable iron covers shall be used with malleable iron boxes
and heavy gauge steel covers shall be used with sheet steel boxes
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All cover and accessory fixing provisions shall be so positioned that the fixing screws lie completely clear
of cable entering the box. All fixing screws shall be of brass (e) all boxes installed in exterior locations,
plant rooms, ducts, etc., shall be fitted with approved type gaskets to provide a waterproof seal between
box and cover or other items fitted to the box.
All boxes provided as junction boxes where cable joints are specified or permitted shall be provided with
fixed terminal blocks. Such boxes shall be of a suitable size to contain the terminal block and sufficient
cable to allow neat connections to be made. The terminal blocks shall be fixed to the box by brass screws
and shall comprise brass conductor connectors, with brass clamping screws enclosed in porcelain or other
heat-resisting insulation material which will not distort or otherwise have its properties damaged by
temperatures below the highest temperature at which the insulation of any cable connected to it is
destroyed.
INSTALLATION OF FLEXIBLE CONDUIT
a. All conduits must be secured to outlet boxes, junction boxes or cabinets by placing locknuts on outside
of box and locknuts and bushings on the inside of box.
b. Conduits connecting recessed fixtures and their adjacent junction boxes must be flexible metallic
conduit 20 mm minimum size and will be of sufficient length to permit dropping of the fixture below the
ceiling and to gain access to the junction box.
c. Conduit to motors will be terminated in the conduit fittings on the motors, the final connection being
made with liquid tight flexible conduit and suitable liquid tight connectors.
d. Installation of flexible conduits in wet areas shall be used waterproof/weatherproof/tight flexible
conduits, if applicable.
CLEANING (CONDUIT SYSTEMS)
The conduit outlets when installed and before wiring shall be temporarily closed by means of wooden
plugs, and immediately before cables are drawn in, conduit systems shall be thoroughly swabbed out until
they are dry and clean.
USE OF CONDUITS IN RESTRICTED EARTH FAULT PROTECTION
The 240 Volts A.C. systems supplying the battery charger shall be taken directly from the MV Panel, by
individual conduit. The return 30 Volts D.C. system from the battery charger to the MV Panel shall be
installed in a separate conduit. Single conduit used for both A.C. and D.C. is not permitted.
USE OF CONDUITS IN DISTRIBUTION BOARDS
All distribution boards shall be flush or surface mounted at a height not exceeding 2.20 meters to the top
of the distribution board from the finished floor level. All conduits used for final circuits shall terminate
directly in this distribution board and not in a trunking section.
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USE OF CONDUITS IN WIRING SYSTEMS
Wiring installed in buildings (constructed of concrete floors with concrete blocks used for walls, partitions
etc.) shall be carried out using P.V.C. cable run in galvanized steel conduit or high impact rigid P.V.C.
conduit concealed within the building fabric.
Prefabricated buildings using concrete wall panels or similar material may be wired using semi rigid P.V.C.
heavy gauge conduit. The jointing of the conduit in the wall to the ceiling or floor slab may be carried out
using a length of flexible P.V.C. conduit provided that this length does not exceed 400 mm.
USE OF CONDUITS IN INSTALLATION OF SUB-MAIN CABLES (ABOVE GROUND)
Non sheathed cables shall be protected by enclosure in conduit, duct or trunking throughout their entire
length.
Cables shall be run in a lift (or hoist) shaft unless they form a part of the lift installation.
Cables for lift installation, other than travelling cables, in such a shaft shall be:
Armored, or PVC Insulated In Galvanized Steel Conduit, or M.I.C.C. / P.V.C. Sheathed.
Every cable installed in or on a building shall be supported by one of the methods described below, and
supports shall be so arranged that there is no appreciable mechanical strain on any cable termination:
1.For non sheathed cables, installation in conduit, without fixing of the cables, provided that precautions
are taken against undue compression of the insulation at the top of any vertical run exceeding 4 meters in
length.
2.For rubber or PVC sheathed cables, installation in conduit, without further fixing of the cables, provided
that any vertical runs shall be in conduit of suitable size and shall not exceed 4 meters in length.
Where cables, conduits, rising main bus bars, ducts or trunking pass through floors, walls, partitions or
ceilings, the surrounding hole shall be made good with cement or similar fire resisting material to the full
thickness of the floor, wall, etc., and space through which fire or smoke might spread shall not be left
around the cable, conduit, duct or trunking.
In addition, where cables, conduits, or conducts are installed in channels, ducts, rising main bus bar
trunking or shafts which pass though floors, walls, partitions or ceiling, suitable internal fire resisting
barriers shall be provided to prevent the spread of fire.
Cables without armour must be installed in rigid P.V.C. ducts or conduits, or alkathene piping of strength
sufficient to resist a glancing blow by a spade. Hose piping or piping made of very soft flexible material will
not be acceptable.
6. CONDUITS
TYPES OF CONDUIT
Only galvanized steel or rigid, high impact, heavy gauge PVC conduit shall be used for any installation
where conduit is to be installed.
No conduits of any kind shall be used for wiring within substation, only M.I.C.C. / P.V.C. sheathed cables
shall be used in these locations. P.V.C. and galvanized conduit shall not be mixed on any length of run
without the prior approval for the purpose by the governing national standards.
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Page 777 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
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NAME:
RIGID METALLIC CONDUIT:
The metallic conduit and its accessories shall form a continuous metallic sheath of adequate strength
surrounding the cables throughout the length of the conduit.
Metallic conduits shall not be run under floor tiles of buildings.
The bores of all conduits shall be smooth and free from projections and/or sharp edges that may injure
the wires or prevent them from being drawn in. The internal edges of the ends of all lengths of conduit
shall be raised or chamfered before assembling into position.
All runs of conduit shall be assembled complete with all necessary accessories and the whole firmly
attached to the structure of the building before any wires are drawn in. All wires shall be drawn through
the covers of inspection and other fittings installed for the purpose.
All thread, vice marks, tool marks, and breaks in the protective coating on metallic conduit and/or
conduit fittings shall be painted with a steel preserving paint immediately after erection.
No run of conduit shall exceed 10 meters between adjacent draw in points, nor certain more than two
right-angle bends, sets, or other deviations, from the straight line.
Inspection couplings or draw in boxes shall be used where necessary in straight runs of conduits for
draw in purposes and shall be placed so that cables can be inspected and, if necessary, withdrawn
throughout the life of the installation.
Where conduit and or conduit fittings are attached to switches, distribution boards, boxes, or other
equipment, smooth bore male brass brushes and flanged couplings shall be used.
Circular or hexagonal heavy locknuts shall be used at all positions where running joints are required and
care shall be taken to see that they seat firmly and evenly into mating faces of couplings or other
adjacent accessories.
Where exposed to water, rain, or weather, all covers shall be arranged or fitted with machined joints
and or fitted with durable gaskets such that water cannot penetrate.
Except where provision is made for fastening, conduits shall be saddled to the structure of the building
within 15 cms of each terminal box, angle box, bend, or other conduit fitting and at intervals, not less
than 1.50 meters couplings and through type drawing boxes shall be counted as part of a straight run of
conduit.
Except where provision is made for fastening, conduits shall be saddled to the structure of the building
within 15 cms of each terminal angle box, bend, or other conduit fitting and at intervals, not greater
than 1.50 meters couplings and trough fitting and at intervals, not greater 15 meters couplings and
trough type drawing boxes shall be counted as part of a straight run conduit.
All box bends and other accessories shall be of the same material as the conduit and shall have the same
protective coatings. Grey cast iron boxes etc. may be used with metallic conduit but shall be finished in
the same manner as the conduit to which they are directly attached.
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MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 778 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
The number of single core P.V.C. insulated non-sheathed cables run in metallic conduit shall be such as
to permit easy drawing of the cables. The actual number of cables drawn into any conduit shall not go
greater than the number given in Table No. 04.
The minimum size of metallic conduits that may be used in electrical installations shall be 20 mm other
sizes of conduits shall be limited to the following diameter: 25 mm, 32 mm, 38 mm, and 50 mm.
Galvanized conduit boxes used for all electrical accessories including light switches and socket-outlet
shall be fitted with a brass earth terminal.
RIGID NON METALLIC CONDUITS:
The rigid nonmetallic conduit may be employed in general electrical installations provided it is made
from polyvinyl chloride or equivalent material that has been certified as suitable for use at ambient
temperatures up to 550 C, non-hygroscopic, and self-extinguishing type.
Rigid PVC Conduit Shall Not Be Used in the Following Locations:
1. Where exposed to the outside ambient temperature.
2. Where it may be affected by chemicals to cause determination in its construction.
3. Any part of a hospital installation for lighting and power circuits.
4. Petrol stations and forecourts.
5. The same room as a diesel generator.
6. Plant room, lift motor rooms and lift shafts.
7. Substations.
The inside and outside surfaces or nonmetallic conduits shall smooth and free from burrs and similar
defects. The interior and ends of conduit fittings shall have no sharp edges and corners, shall be smooth
and well rounded to permit easy drawing in of cable air to prevent any damages to cable insulation.
The entries of nonmetallic conduit fittings shall be so designed that a reliable watertight joint can be
made between the conduit and fittings. Vinyl cement shall be used to make all joints. A vinyl solvent
shall be used for permanent joints and cement shall be used for expansion couplers.
Rigid nonmetallic conduits shall be so constructed that it is possible to bend the conduit easily with the
aid of a bending spring and all conduit and conduit fittings shall be of the unthreaded type.
The minimum size of rigid nonmetallic conduit used for general electrical installations shall be 20 mm Ø.
Other sizes of rigid nonmetallic conduits shall be of the following diameters:
25 mm, 32 mm, 38 mm and 50 mm
The number of single-core P.V.C. insulated non – sheathed cables run in one conduit shall be such that it
permits easy drawing of the cables. The actual number of cables drawn into any conduit shall not be
greater than the number given in Table 04 below:
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
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DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 779 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
A separate insulated earth wire shall be drawn into all rigid nonmetallic conduits for each circuit, the
cables of which pass through the conduit.
Rigid nonmetallic conduits shall be installed generally in accordance with the requirements set out for
metallic conduits shall allow for the longitudinal expansion and contraction of the conduits.
Where a lighting fitting is suspended from a nonmetallic conduit box, care shall be taken to ensure that
the temperature of the box does not exceed the permitted safe temperature of the material and is fitted
with screwed metal insert clips. The mass suspended from the box shall not exceed 2 Kg.
Electrical conduits that were required to be distinguished from pipelines of other services, shall use
orange as the basic identification colors. P.V.C. conduit boxes for all electrical accessories including light
switches and socket outlets etc. shall have fitted brass fixing sockets tapped for 3.5 metric threads.
FLEXIBLE CONDUITS:
Flexible conduits may be employed for connecting electrical motors and other equipment subject to
adjustment of position and vibration to the fixed wiring. Flexible conduits may be of the metallic type
only. Metallic flexible conduits shall not be used as the sole means of providing earth continuity and a
separate earth continuity conductor of appropriate size shall be provided.
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MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
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METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 780 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
In damp and wet locations all flexible conduits shall be of the type that prevents the ingress of water
and moisture.Flexible conduits shall only be run exposed and shall be so positioned that they are not
susceptible to mechanical damage. Necessarily flexible conduits shall be adequately supported. The
ends of flexible conduits shall be securely anchored to the fixed conduit or equipment to which it is
attached by approved flexible conduit adapters that maintain effective mechanical continuity securely in
position without distorting it. The flexible conduit shall not be used as part of the earth conductor. A
separate earth conductor shall be installed to comply with the same requirements for rigid conduit
installations.The maximum length of a flexible conduit run shall be 2.50 meters. Where flexible conduit
is installed less than 1.50 meters above a floor in a position where it may be easily disturbed or reached,
it shall be supported at intervals not exceeding 300 mm, except where terminating at motors or at other
equipment which requires a free length of flexible conduit to provide for normal movement.
SEGREGATION OF CIRCUITS
These Types of Circuits Shall Be Divided into the Following Categories:
Category No. 01 Circuits: Circuits other than fire alarm circuits operating at a medium voltage and
supplied directly from a mains supply system.
Category No. 02 Circuits: All low and extra low voltage circuits.
Category No. 03 Circuits: Fire alarm circuits.
Category No. 04 Circuits: All telecommunications circuits e.g. radio, telephone, sound distribution,
burglar alarm, bell, and call circuits which are not supplied directly from a mains supply system.
Cables of Category No. 01 circuits shall not be drawn into the same conduit, pipe, trunking, duct, or run
on the same cable tray, as cable Category No. 02 unless the latter cables are insulated to the same
degree for the highest voltage present the Category No. 01 circuits.
Cables in Category No. 04 circuits relating to their own specific system shall be installed remotely from
another in their own conduit, trunking duct, or pipe. Cables in Categories 02, 03, and 04 shall not, in any
circumstances be drawn into the same conduit, or duct.
SUSPENDED FALSE CEILING INSTALLATIONS
Light fittings shall be supported by one of the following methods:
1. Direct support from the false ceiling framework (Providing the ceiling has been designed to withstand
the weight of the light fittings). When using this method it shall be possible to completely withdraw the
light fitting from the ceiling without damage to the ceiling or reducing its rigidity.
2. Metal conduit support from the underside of the structural slab. A fluorescent fitting shall have a
minimum of two conduit support. Each conduit shall terminate at the fitting by means of a screwed
coupling and male brass bush to give leveling adjustment of the fitting.
Wiring to the light fitting shall be run within the conduit system where the loop in principle is used.
Direct to Soffit of Structural Slab
Light fittings shall be secured directly to the conduit box. Where enclosed tungsten light fittings are fixed
directly to a P.V.C. high impact circular conduit box, steel insert clips must be used for the light fittings to
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
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METHOD STATEMENTS
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PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 781 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
the box. The method of using the normal fixing inserts is not approved due to the heat transfer from the
fitting to the P.V.C. box. Two conduit box fixings shall be required on fluorescent fittings greater than
600 mm in length.
Fire Alarm Systems
M.I.C.C. /P.V.C. sheathed or any other cables approved by governing national standards only shall be
used for fire alarm installations. This applies to push buttons, bells, heat detectors, smoke detectors
associated with the installation. For control panel displays and monitoring, P.V.C. /S.W.A. cable or P.V.C.
cable in a galvanized conduit may be used.
7. HEALTH SAFETY AND ENVIRONMENT CONTROL FOR ELECTRICAL CONDUITS AND BOXES INSTALLATION
A. HSE Risk Assessment
Please refer to the attached document in Appendix A and to these guidelines.
B. Permit and Licensing Requirements
The required permit to work shall be obtained prior to the commencement of work. This shall be
coordinated with HSE.
C. Pre-Start Safety Briefing Arrangements
C.1 Protective and Safety Equipment
All workers Involved shall be equipped with adequate PPE as stated below: Safety Helmet with Company
Logo
Safety Boots
High Visibility Vest
Safety Goggles
Hand Gloves
Coveralls
High voltage gloves
High voltage Rubber Mat
Proper safety harness
C.2 Information to Personnel
Safety Induction
Job training
Superintendents Notices/Memos
Toolbox talks
STARRT Card
C.3 Special Safety Requirements:
All necessary personal/protective equipment (PPE) as well as harness be provided.
Rigging Team, wearing distinctive vests, shall be assigned to help operators maneuver their equipment.
The equipment operators shall possess the required licenses and certificates.
Generated dust shall be controlled by periodic water spraying.
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FORMATE ID:
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METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 782 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
The required permit to work shall be obtained prior to commencement of work.
The project safety officer is responsible along with the project zone site engineer for ensuring that all
operations are carried out with due regard to the safety of all project personnel & property.
Working at height to be monitored with due care.
In case of working at night, please refer to Method Statement for Night Works
8. QUALITY ASSURANCE AND QUALITY CONTROL – METHOD STATEMENT OF ELECTRICAL CONDUITS
AND BOXES INSTALLATION
A. QUALITY ASSURANCE REQUIREMENTS
The contractor shall provide the required documents for the Consultant’s approval prior to initiating the
execution of this activity as per project Specification.
The Quality Control requirement shall include related to ITP’s and other related documents as applicable.
Refer to Inspection Test Plan (See Attachment B)
Applicable codes and standards referenced for materials and installation in the method statement for
electrical conduits and boxes installation.
B. QUALITY ASSURANCE PROCESS
The contractor shall notify the Engineer 24 hours in advance prior to the start of activity and comments
from the Site Instruction will be complied with the satisfaction of the consultant.
The contractor shall consult the public utility authorities not less than one month before it is proposed to
commence work to ascertain whether any underground installations will be affected by the proposed
work, in which event the contractor shall make all necessary arrangements with the public utility
authorities to safeguard the installation.
C. FOLLOW UP AND EVALUATION
Follow-up on quality performance shall be carried out through an in-house monitoring system such as
progress reporting to the planning department, daily, weekly and monthly reports generated by the
planning department to closely monitor site performance.
All the above shall be conducted in close coordination with the quality department to monitor any
deviations from the Quality Management System requirement and induce corrective actions whenever
required to eliminate non-conformance or quality deviations.
D. RECORDS
Checklists (CL)
Inspection Request (IR)
Other Project related reports.
9. ATTACHMENTS IN THE DOCUMENTATION FOR METHOD STATEMENT OF ELECTRICAL CONDUITS AND
BOXES INSTALLATION
A. APPENDICES
Appendix A: HSE Risk Assessment for Installation of Electrical Conduits and Boxes
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 783 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
Appendix B: Inspection and Test Plan for Installation of Electrical Conduits and Boxes
Appendix C: Checklist for Installation of PVC Conduits and Boxes
Appendix D: Checklist for Installation of G.I Conduits and Boxes
Appendix E: Permanent Material Delivered Approval form
METHOD STATEMENT FOR
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
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S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 784 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
MANHOLE CHAMBERS
SR. EFFECTIVE REV. MSS MANAGER MSS PROJECT CLIENT
CLIENT QA/QC
NO. DATE NO. QA/QC MANAGER SUPERVISOR
MANHOLE CHAMBERS
PURPOSE
This Method Statement for Construction of Manhole Chambers, Bases, and Appurtenances is the
systematic procedure in safely performing the detailed installation of precast manholes and
appurtenances ensuring that quality control objectives are maintained.
This method statement also covers, in brief, the installation procedure with respect to approved shop
drawings, design drawings, manufacturer recommendations, and in accordance with project
specifications. Execution is not limited to the following scope of works and varies as the construction of
manhole advances to the finishing stage which includes:
Survey
Trench Excavation
Installation of Permeable Geo-textile
Installation of Underground HDPE Perforated Pipes
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FORMATE ID:
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METHOD STATEMENTS
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PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 785 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
Construction of Manhole Chambers and Bases
Installation of Manhole
Benching
Backfilling
The method statement provides guidance for assessing the activities i.e. transportation, handling storage,
site preparation, installation, and inspection. This guidance is based on the requirements set forth in the
HSE Plan and the Quality Assurance Program (QAP).
This method statement will be implemented in conjunction with the related manhole construction
methodology. Wherein example of these is the typical section for drainage and manhole construction as
per the approved shop drawings.
1. THE SEQUENCE OF WORKS FOR THE METHOD STATEMENT FOR CONSTRUCTION OF MANHOLE
Prior to installation, it must be ensured that:
All relevant documentation such as Approved Shop drawings i.e Underground Manhole Construction
Detail, Method Statements, ITP’s, and Checklist.
Method Statement etc. and the material applicable to a particular section of work will be checked by the
Site engineer prior to the commencement of work ensuring that these are of the correct type as reviewed
by the Engineer.
Approval of the manhole production schedule will be submitted and obtained.
All necessary documents, such as a work permit and other relevant QC inspections to be carried out, shall
be obtained prior to the commencement of the concrete manhole works.
Before commencement of installation of soak away network, a Material inspection of the soakaway
system will be carried out prior to being withdrawn from the storage area i.e. quantity, physical damage
and brand/make.
Before the beginning of the installation, it will be ensured that the approved valid Permit To Work (PTW)
is available on site.
The engineer in charge will ensure that approval and standard tools and tackles are available to carry out
the work.
Safe access to work areas will be provided and will be approved by the competent safety person prior to
the commencement of works if applicable.
Check the work area tidy and remove flammable materials if any and a safe environment will be ensured.
Where the Risk Assessment identifies high-risk works a permit to work will be obtained from the safety
department.
The HSE Manager and the Safety Supervisor shall carry out safety site inspections to ensure that the
safety specifications set out in the Safety Management Plan are complied with during the execution of
precast concrete manhole work.
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Page 786 of 864
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MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
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Persons engaged in precast concrete manhole work shall be supplied with and used with the requisite PPE
and as a standard, each person shall wear safety helmets and safety footwear, etc. The requirement for
personal protective equipment shall be approved by the client representative
Competent manpower and builders will be employed to carry out the installation work.
Necessary civil clearance will be obtained (if applicable) prior to the start of installation.
For loading and unloading operations, the proposed crane location is to be ready with a compacted floor
for the safe positioning of crane and boom trucks.
The boom truck loading capacity and certificates will be ensured prior to the start of the loading.
2. MATERIAL TRANSPORT AND HANDLING
All materials involved in the soakaway network will be handled and transported and unloaded at the site
strictly as per the manufacturer’s instruction.
After delivery, equipment will be inspected for any transport both internal and external precast manhole
components casing damage, in compliance with project specification & materials submittal.
All the accessories will be tagged, crated, and protected for shipping as per the manufacturer’s
recommendation.
Approved shop drawings will be posted at the workplace for site reference used and installation works.
3. STORAGE
HDPE Pipes need to be stored in a shaded area or protected with a tarpaulin covering.
Waterproofing membranes will be stored vertically in well-covered and ventilated places not subject to
direct sunlight.
Any discrepancies, damage, and etc, found to the materials will be notified and reported to QA/QC
Engineer.
Materials found not suitable for site use will be removed immediately.
Replace materials that are damaged or unfit for use.
No materials will be permitted to enter the work location without being inspected and approved by the
Engineer.
4. PIPE AND MANHOLE TRENCH EXCAVATION
SURVEY/SETTING OUT
Setting out of the proposed manhole position will be provided as per the latest approved shop drawings
and design drawings. This activity is applicable for various sizes and depths of manholes such as for
example:
-1500mm diameter manhole opening on 200-500mm diameter surface waterlines up to 6m depth
-2000mm diameter manhole on 600-900mm diameter surface water lines of depth more than 6m
Marking shall be done according to excavation site area with coordinates by permanent marker or will
use steel pins (12 mm dia. steel bars with safety cap) to secure points given on the cross-section and
along the longitudinal direction.
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Page 787 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
Contractor to provide the as-built survey record drawings including the existing underground utilities
and existing manhole in the vicinity of work once it is completed.
Surveyor will recheck to ensure that finish levels are acceptable. Any discrepancy in the levels, action
notice is issued and work is rectified as per requirement.
During pipe laying, if the alignment deviated within the permissible limit, the manhole will be adjusted
so that all the lines should be at the center of the manhole as well as the invert level is according to the
approved profile shop drawing.
The contractor will provide proper access for other traffic (like a pedestrian) where the pipeline works in
construction access roads and road crossing within the manhole construction area.
UTILITIES SCANNING
Buried / existing utilities to be scanned, identified, and marked on the area using markers.
If any unidentified utilities have been detected during scanning and excavation, then machinery work
will be stopped and will be reported to the site in charge.
Based on permission, only an authorized person shall work near utility lines.
Besides any utility line, the excavation shall be cleaned by manual excavation. If possible the use of a
manhole box for shoring during the excavation should be implemented.
If any damage occurs to an unidentified utility line during excavation, then it will be reported to the
emergency number immediately for temporary mitigation and permanent mitigation to be done after
reporting to the authorized department then take necessary approval.
As-built has to be recorded and updated by the contractor if any changes as per site condition.
TRENCH EXCAVATION
Excavation of trench shall be done as per the approved methodology for trench excavation.
The excavation levels will be carefully checked/verified and recorded by the surveyor prior to start-up to
ensure achievement of formation level of manhole and manhole chamber which are approximately 130
mm below the slab (allowing for 75mm thick blinding and 50 mm concrete screed under the base and
waterproofing membrane or up to the required depth.
PERMEABLE GEOTEXTILE INSTALLATION
Approved material shall be used.
The application shall be in accordance with manufacturer recommendation and as indicated in the
approved shop drawing.
Prepare and cut the geotextile to the proper width prior to the installation of the trench drain.
Place the prepared geotextile along the excavated trench.
Anchor the edge of the geotextile with heavy objects or pin the geotextiles on the ground to prevent
movement of the geotextile during the installation process.
After the geotextile surround installation, the trench will be filled with gabbro aggregate up to the
required bedding level of perforated HDPE pipe.
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To prevent slippage of the overlapping fabric, the areas of overlap shall be stabilized, as approved by the
engineer, with pins, anchor blocks, or piles of aggregate.
INSTALLATION OF UNDERGROUND HDPE PERFORATED PIPES
Related installation of underground HDPE perforated pipes shall be done as per approved methodology.
Bedding and Surround:
Bedding material shall be in accordance with the project specification and approved shop drawing.
20 mm granular material shall be used as per approved material submittal.
Completion of pipe surround: Gabbro shall extend from not less than 150 mm beneath the pipe and 300
mm above the crown of the pipes in accordance with the latest approved shop drawings.
Relative to laid bedding, a plain concrete cradle will be constructed to support the pipes.
Pipe Laying with Gravel Surround
Drawings shall be reviewed by the Engineer and shall be communicated to the site in charge of the pipe
laying. The pipes will be laid out in accordance with the instructions of the manufacturer and as per
project specifications.
Prior to this, the written inspection requests will be submitted to the Engineer/Inspector for approval of
the various stages of the work.
The bedding material with a thickness of 150 mm as directed by the Engineer shall be spread and
leveled to the gradient of the pipe at a depth of 2.0 cm above the inverted level.
The pipes shall be laid in a granular bed and surrounded by aggregates of 10 mm maximum in sizes then
contained within the approved geotextile trench liner material.
For the safe setting out of the pipelines, the stalked pipes will be lowered and laid down from the
downstream side to the upstream direction.
The pipes will be checked for line and level jointly by the contractor’s and consultant’s surveyors
respectively.
Each pipe joint shall be enclosed with an approved PVC wrapping tape. Side bedding is carefully placed
by means of a crane and side discharge skip, discharging the material centrally.
Subsequently, the pipe surround material will be carefully placed in two layers at a level of 30 cm. above
the crown of the pipe and compacted. The overlapping of the geotextile sheets will be 30 cm.
Selected materials previously excavated from the trench will be used for the trench backfilling in 150
mm layers, carefully compacted by hand rammers, up to a level of 600 mm above the crown of the pipe.
The water test shall be carried out in accordance with the project specifications.
When pipe laying is not in progress, the pipe ends will be closed by wooden plugs.
Backfilling will continue in layers, compacted in the lower parts by mechanical plate compactors and in
the upper parts by hand-operated drum rollers.
The deflection test will be carried out immediately after the completion of backfilling activity.
GENERAL PROCEDURE FOR THE CONSTRUCTION OF MANHOLE CHAMBERS AND BASES
Precast manhole units as per standard details approved with the internal coating will be used.
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NAME OF CLIENT: KAMOA COPPER S.A.
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Safety procedures will be followed as outlined in the safety manual and risk assessment submitted and
will generally comply with the requirements.
Both precast manholes shall have a circular base unit over which a circular shaft shall be built. The base
is going to be cast in one part.
Upon receipt of the Engineer’s approval for the formation, the concrete blinding shall be poured to a
depth of 50 mm and the trowel shall be finished to a height of 55 mm below the manhole invert. Prior
approval will be sought from the Manhole Production Schedule.
The ‘torch-applied waterproofing membrane (5mm) will be mounted in compliance with the
manufacturer’s instructions.
The membrane will be covered by a 50 mm screen.
Precast base pre-painted is set to line & level followed by shafts, adjustment rings cover slabs
The fixing process shall be maintained by fixing 2 no. Gasket strips with a width of 20 mm between each
joint.
The 250 mm thick, removable concrete class b cover slab with a circular opening of 600 Ø is excentric.
Its D.I. cover & frame as defined will be fixed to line & level as per the approved details.
GENERAL METHOD FOR MANHOLE CONSTRUCTION
Upon completion of the screed, the steel reinforcement for the base unit shall be cut, bent, and installed
at the steelyard as per approved shop drawings as well as the approved bar bending schedules.
After fixing the mold for the manhole steel cage, the casting will be finished.
Proper curing of the precast element will be observed.
It will then be taken to the site and raised above the screen with the aid of a crane.
Frame and cover fixing shall be as specification and our D.I. cover & frame Fixing Method Statement.
INSTALLATION OF PRECAST MANHOLES
1. BLINDING CONCRETE GRADE SRC 25
For setting out, the site engineer will be ensured that a specific area/location is handed over to proceed
with concrete operations at the site. The survey will be carried out for marking of coordinates & levels.
Using GPS based on the Total Stations instrument, mark each manhole construction coordinates of the
concrete element or structure using permanent markers as shown in the approved drawing lay-out.
For blinding concrete, a blinding concrete of (SRC C20/25) as per approved design mix and thickness and
as indicated on approved drawings will be placed over the final excavated level as per approved drawing
locations. Blinding concrete will be protected with approved waterproofing primer and membrane as
per approved material. The application will be according to the manufacturer’s recommendation.
Blinding is then placed, spread with shovels, and rakes leveled/compacted by tamping with aluminum
straight edge bars, the top of the blinding concrete will be steel float finished to provide a suitable
surface for torch-applied membrane. Curing is carried out by water ponding or curing agents, covered
with hessian cloth.
2. WATERPROOFING
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
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DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 790 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
Prior to waterproofing activities, the contractor will ensure that the concrete element has completed
the curing period as stipulated in under method statement of cast in-situ concrete.
The contractor will ensure that delivered waterproofing material follows the approved material
submittal, and material inspection request (MIR) has been raised and approved by Supervision Engineer.
For the installation of waterproofing at the manhole, the waterproofing application shall be
implemented as per the approved method statement for waterproofing.
ERECTION OF PRECAST MANHOLES
The survey team should have established the precast concrete manhole true coordinates and elevation
prior to the placement.
Precast installation shall be checked and verified to its dimension and elevation prior to placement of
the precast concrete manhole, erection must follow manufacturer instruction unless otherwise
indicated in the approved shop drawing.
Crane shall lift the precast elements from the trailer directly to its final location and coordinates already
established by a competent surveyor.
Fitting of manhole chamber ring: Make sure that the joints are clean and free from foreign objects
before fitting the next manhole chamber ring (shaft) unit. Two strips of 20 x 25 bitumen-based flexible
strip sealant shall in placed prior to mounting. Repeat with further ring units until the chamber has been
constructed to the required height.
Once completed, verify the alignment and correctness of the elevation of each newly installed/placed
precast concrete manhole, in layman’s terms, use a string line can be used to align the manhole. Proper
alignment shall be confirmed before releasing the manhole base from the crane.
After the completion of placement is done and has been verified, checked, and confirmed, all lifting
devices shall be recessed. Lifting devices shall be removed and patched to match the interior face of the
manhole after installation is complete. Lifting hooks shall be filled with non-shrink mortar.
After the execution of shaft installation, a pre-cast cover slab shall be installed.
Place external precast manhole (reducer slab) cover slab on top of the last pre-cast manhole wall
segment.
If the pre-cast shaft is equipped with the backdrop, all HDPE pipe fittings shall be installed and shall offer
for inspection and taking approval. The concrete box will be constructed to complete the encasement.
MANHOLE BENCHING
Manhole floor benching is made after pipes installation with manholes walls, where site made plywood
shuttering (where needed) will be placed to the dimensions shown in approved shop drawings, Grade
SRC C20/25 concrete of an approved mix will be poured by means of a concrete pump or manually, top
of surface will be working with a good finish. Shuttering will be removed 24 hrs after casting and curing
similarly. The benching is carried out after the pipe installation.
WALL SURFACE FINISH AND PAINTING TOUCH UP
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Manhole chambers’ internal concrete surface shall be repaired against any uneven surface. Applicable
method statements shall be submitted separately.
DUCTILE IRON MANHOLE COVERS
The ductile iron cover frames are placed on pre-cast concrete seating rings/blocks that are positioned
above the edge of the opening of cover slabs. After properly mounting the cover frame and mortar is
placed all around the precast rings and frame to the dimensions shown in approved shop drawings,
Finally, a manhole cover will be installed.
Elevation of manhole cover, frame, and basic manhole chambers shall be as per the approved shop
drawing.
INSTALLATION OF ACCESS LADDER
Installation of GRP ladder will be approved material and will be supplied by the approved experienced
manufacturer and will be purposely made to suit the depth of each installation as shown in the
approved shop drawing and furthermore, the installation shall be in line with the manufacturer’s guide
for installation.
BACKFILLING
Backfilling will be carried out according to the approved method statement.
The chamber/base slab is not to be backfilled until all required inspections are performed and until the
engineer has verified the works have been done as per approved shop drawings and in accordance with
project specifications.
After approval from the supervising consultant, backfilling shall start after the erection of the manhole
shaft. A small equipment shaft is used for compaction to avoid damage to the shaft tanking membrane,
like tamping rammer, as required.
A compaction test (FDT) will be carried out for the backfilling to obtain a minimum of 95% of the
maximum density for the materials. The test shall be conducted in each layer.
Marking will be done on manholes to control the thickness of compacted layers.
Backfilling shall continue uniform around the shaft to ensure stability during backfilling over the effective
length of the trench.
5. INSPECTION RELATED TO METHOD STATEMENT FOR CONSTRUCTION OF MANHOLE
Mock-up and subsequent inspection shall be offered to supervising consultant for approval.
For surface water drainage system, storm manhole, HDPE pipes, and fittings shall be inspected in
accordance with the Inspection and Testing Plan and Inspection checklist.
The inspection may be made on isolated portions of piping from manhole to manhole as well, to facilitate
general progress in construction.
All open-end shall be sealed off after inspection is carried out successfully. The inspection shall be
recorded and witness by supervising consultant with the corresponding Work inspection request (WIR).
6. QUALITY CONTROLS
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The Inspection and Test Plan (ITP) for this Method Statement for Construction of Manhole summarizes
various characteristics to be checked. The concerned Site Engineer or Site Supervisor will be responsible
to ensure compliance for this manhole construction and the site QA/QC Engineer will carry out quality
control checks and report the inspection results.
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METHOD STATEMENT FOR
ELV (EXTRA LOW VOLTAGE) SYSTEM
SR. EFFECTIVE REV. MSS MANAGER MSS PROJECT CLIENT
CLIENT QA/QC
NO. DATE NO. QA/QC MANAGER SUPERVISOR
ELV (EXTRA LOW VOLTAGE) SYSTEM
PURPOSE
This Method Statement for ELV (Extra Low Voltage) system defines the procedures for the installation of
external underground ELV services up to tie-in point/access control panels of the building ensuring that job
execution complies with the Project Specifications, Quality, Health & Safety standard practices.
The scope of this method statement includes:
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Methodology for installation of all the electrical system containments for ELV systems externally which
comprise of a variety of sub-systems like:
Data transmission IT Networks; Local Area Networks (LAN) using Fiber Optic, Copper or Wireless
CCTV/ IP Surveillance
Building Management System (BMS)
Sensors & Alarm System
Vehicle Access Control
Telephone: Voice & Video Intercom
Door Access Control
Lift Access Control
IP Clock System
Lighting Control System
Toilet Alarm System
HVAC Control
Fire Fighting System – Fire alarm system
Public Address Broadcasting
Disabled Toilet Alarm and Call System
Voice Evacuation System
Tour Guard Patrol
Public Address System/Call System
Parking Management
Audio Visual System (Auditorium/ Conference Halls)
Equipment, approved documents, and approved materials used
Checklists, Inspection, and Test Plans as part of the Project Quality Plan
Quality Control Procedure and Quality Management System for ELV services
HSE Assessment & Job Hazard Assessment, Construction Risk Assessment
1. THE WORK SEQUENCE OF THE ELV SYSTEM
The following methodology is for UPVC/HDPE duct installation, cable laying for underground extra-low
voltage system (ELV) up to tie-in point/access control panels.
MEP team will only come in after receiving clearance from other disciplines to start the underground
duct installation and cable laying.
DELIVERY OF MATERIALS, STORAGE, AND HANDLING
1. The wooden drums will be always carried vertically. They will be fixed and properly chocked with care on
the vehicle, on the wagon and on the ship, in order to avoid any exterior chocks.
2. The unloading and the different handling will be done carefully with lifting equipment’s. – In case of
handling with a crane, an axle is used in crossing the drum centre, lifted from both ends by two slings. It
will have a length equal, at least, to the width of the drum. It is prohibited to put the slings on the lags.
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In the case of handling with a forklift truck, the drum is put vertically with care on the forks, never let a
drum fall during all kinds of unloading, and do not place any weight on the drums.
1. When the cable drums are arriving on-site, it will be checked especially.
2. The good order of the lagging and of the end caps of the cables (breaking of a wooden lag could tear the
outer
3. Deliveries will be Inspected and handled at the site area according to the given instructed requirements.
4. All UPVC/HDPE ducts, fitting accessories, utility structures, and cables will be covered and stored above
grade in a secure and protected location in order to be protected from climate, dust, and entrance of
debris and will be codified for easy traceability.
5. Ensured that the proposed storage area for the materials is cleaned.
6. Separate areas in the storage zone will be marked for different materials.
7. Ensured that the material is stored in a shaded area to protect it from exposure to direct sunlight.
8. Ensured that the lifting equipment is adequately rated for the specked weight (shown on the rating plate)
and fit for purpose.
9. Verify that the bracing & supports are provided to prevent damage during transit, lifting, or unloading.
10. All materials received at the site will be inspected by the Consultant and Contractor’s QC inspectors/QC
Electrical inspectors with the corresponding Material Inspection Request (MIR) issued.
11. Ensured the drums to be moved in an upright position and the fork will be longer than the width of the
drum. When moving the drums, tilt the truck mast so that the drum remains in the fork and the points
don’t touch the ground. Raise the forks of the forklift at least 6-8 inches from the ground surface.
12. Don’t release the forks until the truck has stopped completely. Keep sufficient space between the drums
so that forks don’t damage the other drum
DRUM TRANSPORTATION, UNLOADING AND STORAGE
1. During transportation, the cable drums should not be kept in a flat position; it crushes down the layer of
the cable, resulting in breakage
2. The cable drums should always be kept in an upright position and be tied with a chain or belt with
wooden blocks that should be kept in between the flanges of each drum to avoid any jerks/ movements
during transportation.
3. While unloading trucks it is important that the cable drum should not be dropped directly on the floor.
4. The weight of drum & cable may cause deflection of drum flange resulting in flattening, deformation, or
damage of cable.
5. The drum will be rolled from the truck on to receiving platform, which should be at the same height as
the tailgate of the truck. An alternate is to use a forklift to unload drums from the truck
6. The drums should always be stored in an upright position. The storage of drums in an alternative position
can lead to winding defects.
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7. If storage place is limited and it becomes necessary to stack, then stack the completely wrapped on their
flanges. Stacking is allowed only for the drums whose flange diameter is 1250mm or less. Do not store
drums on flat flanges.
8. The cable drums will be stored on a well-drained, hard surface so that the drums do not sink in the
ground causing rot and damage to the cable drums. The paved surface is preferred, particularly for long
term storage.
9. The drums will always be stored on their flanges, and not on their flat sides.
10. Both ends of the cables should be properly sealed to prevent the ingress/absorption of moisture by the
insulation during storage.
11. Protection from rain and sun is preferable for long term storage for all types of cables.
12. There should also ventilation between cable drums.
2. INSTALLATION PROCEDURES FOR UNDERGROUND EXTERNAL ELV (EXTRA LOW VOLTAGE) SYSTEM
EXCAVATION
Excavation and preparation of trenches for the installation of duct banks and other underground utility
services will be in accordance with the Project Specifications.
1. Permit to Work (PTW) will be raised for the excavation clearly mentioning the location of work, size of
excavation, and levels.
2. The area of excavation will be cordoned off using safety devices.
3. The size of the trench will depend on the number of circuits and conditions of the site.
4. The depth of excavation for the trench of the underground ELV cables will depend on the number of
UPVC/HDPE pipes as per the approved shop drawings.
CLEARING AND GRUBBING
1. The Contractor will excavate and remove surface material such as debris, windblown sand, vegetation,
and any other unsuitable material in the areas and to the thickness instructed by the Client’s
representative. Clearing and grubbing will be restricted to removal of surface material and debris and will
not include the excavation of natural ground unless directed by the Client’s representative.
2. The removed material will be loaded and transported to an approved dumping area.
3. All surface objects, trees, stumps, roots, and other protruding obstructions not designated to remain will
be grubbed and cleared.
4. In areas inside of the grading limits of cut and embankment areas, stumps and nonperishable sold
objects will be cut off not less than one meter below the subgrade level in the area.
PRE-INSTALLATION
Before the commencement of installation, the following are required to be carried out:
1. Drawing for external ELV work will be approved and will be coordinated with other services.
2. Proper access will be provided as per the approved program.
3. The location/area will be ready for site installation.
4. Prior to the installation, the area where the items to be installed will be inspected
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5. Prior to the installation, check all cabling as per approved wiring detail drawings.
6. Mark the device/panels location and leave enough length of cable at both ends for termination.
7. All installation details will be agreed upon with the Engineer and will be subject to his approval prior to
the commencement of work. The Specialist will obtain an inspection certificate from the manufacturer or
its authorized representative towards the satisfactory installation of the system.
8. Coordination drawings will include multi-discipline activities:
a. Underground Services and Substructure
b. External Utilities and Final Connections
EXCAVATION AND PREPARATION OF TRENCH
1. Excavation and preparation of trenches for installation of duct banks and other underground utility
services will be in accordance with the Project Specifications
2. If dewatering is required for trench preparation, this will be performed
3. Trench depth to be excavated will be as per IFC drawing detail unless otherwise specified.
4. Clean trenches of organic material, root, trash, lumber, and debris. etc., prior to duct installation.
5. Place approved bedding material to the extent necessary for establishing the correct elevation at all
locations where the bottom has been excavated below indicated grade.
6. Prepare and compact the trench bottom such that the duct pipes can be placed to the specified line and
grade, with full uniform bedding, when required.
7. Final invert level elevation will be discussed and finalized by the site engineer based on the approved
shop drawings.
8. The trench preparation will be checked for the required depth, width, elevation, slope, and will be free
from rock, large stones, and any other sharp projections.
TRENCH INSTALLATION
1. ELV cables installed inside UPVC/HDPE underground duct will be free from any damages.
2. Trench sizes will be made as per the approved IFC drawings and as per the suitable trench size.
3. Inspection by the Consultant Representative has to be done for each stage.
4. Place approved bedding material to the extent necessary for establishing the correct elevation at all
locations where the bottom has been excavated below indicated grade
5. Good coordination with the civil team has to be done.
6. Distance between the UPVC pipes during installation should be respected.
7. The bottom of the cable trench will be covered, to a depth not less than the diameter of the largest
cable, with a bedding layer of sand or fine soil.
8. Draw rope of 6mm diameter to be provided throughout all the ducts.
UPVC/HDPE DUCT INSTALLATION FOR UNDERGROUND ELV CABLES
1. It will be ensured that all work is completed and the site is cleared from all disciplines to install ELV
cables.
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2. Prior to the installation of duct-pipes, the trench preparation will be checked for the required elevation,
slope, and free from rock, stones, and other deleterious materials. The installation will not be started
until unsatisfactory conditions have been corrected.
3. Final invert level elevation will be discussed and finalized by an electrical engineer and civil engineer
based on the approved shop drawing.
4. Proper approved materials will be used according to the material submittals: (Submittal References here)
5. Ducts will not be filled with cables to more than 60% of their capacity. Nylon drawcords will always be
left in ducts.
6. The trench width and size are done as per the approved IFC drawing
7. The trench should be sand bedded for 100mm for ICT & ELV as per IFC Drawings and then duct
separators are used for underground ducts.
INSTALLATION DETAILS OF ITS NETWORK
1. The ITS duct banks installed under the carriageway are concrete surrounded by Grade SRC 20 as per IF
drawing.
2. Make joints in ducts and fittings are watertight according to manufacturer-recommended accessories
installation method.
3. Use approved backfill material and provide approved warning tape: 200-300 mm as per IFC Drawing.
4. Make joints in ducts and fittings watertight according to manufacturer written instruction.
5. Stagger the joints of multiple layers of conduits so as not to create a weak point in the duct run
6. Bell mouths are installed at each end of the duct pipe
7. Wipe the duct dry and clean before joining. Apply full even coat of suitable adhesive to the entire area
inserted in the fitting. Allow joint to cure for 20 minutes, minimum
8. Install no more than equivalent of two 90-degree bends between pull points.
9. Duct pits or manholes will be provided at each change of direction and in any case at the distance not
exceeding 30 meters. Segregation of services ducts will be maintained as per Project Specifications.
10. Band ducts together before backfilling.
INSTALLATION DETAILS OF TELECOMMUNICATION NETWORK
1. All the duct route are as per the approved IFC Drawing
2. Where the ducts are laid under the carriageway, the bottom of the trench to be compacted 95% of MDD
or as per by the IFC drawing.
3. Prepare and compact the trench bottom such that the telecommunication duct pipes can be placed to
the specified line and grade, with full uniform bending, when required.
4. Draw rope of 6mm diameter to be provided throughout all the ducts.
5. All ducts to be tested with brush and mandrel as per Project Specification after final compaction
INSTALLATION DETAILS OF ICT & ELV NETWORK
1. The ELV duct banks will be installed under the carriageway with a protection slab of concrete of grade
SRC 30.
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2. Make joints in ducts and fittings are watertight according to the manufacturer-recommended installation
method.
3. Provide 50mm horizontal spacing and 50mm vertical spacing between duct bank/ conduits installed in
the same trench and a clearance of at least 300mm from all other services.
4. Install duct spacers to keep conduits locked together and to prevent sagging and deforming of ducts.
Secure spacer to ducts to prevent displacement during concrete pouring.
5. Terminate duct runs with end cap/ duct coupling for new future extension.
6. Install pull-string inside each empty duct run with enough slack at each end for future cable & cable tray
installation works.
7. Seal both ends of duct bank with plastic end cap/ sealing plug which will be left in place until cable laying
work begins to avoid dirt and foreign materials from entering during and after concrete pouring
8. Prior to concrete pouring, perform the inspection with the Consultant Representative for approval before
proceeding further.
9. Immediately after placing of concrete, pull through each duct a mandrel not less than 300mm long and of
a diameter of 6mm less than the internal diameter of the duct, followed by a stiff bristle brush to remove
all sand, earth, and other foreign matter.
10. Work the mandrel through the ducts carefully to avoid disturbing or damaging ducts where concrete has
not set completely. Pull a stiff bristle brush and a swab to remove water, mud, and fine sand through
each duct immediately before pulling in cables.
11. All duct banks at the limit of works will have end caps installed to prevent unwanted materials from
entering the duct and the chamber network and assisting future connection and network extension.
INSTALLATION DETAILS OF SECURITY SYSTEM NETWORK
1. All ducts under the carriageway will have concrete slab protection according to Security System
Standards.
2. Provide suitable pull string in each empty duct except sleeves and nipples.
3. Use suitable caps to protect the installed vacant duct against the entrance of dirt and moisture.
4. After sanding, warning tapes for the duct banks and cables are provided as per the approved shop
drawing.
5. The proposed location of ducts and manholes for the project is tentative only. Its the contractor’s
responsibility to finalize the location of the duct at the site, in coordination with other new services.
INSTALLATION OF UNDERGROUND ELV CABLE THROUGH DUCT
1. Before cable pulling commences, the actual length of the route will be measured and checked to ensure
the adequacy of the provided cable length. The system will be installed by a contractor licensed to carry
out such installations and be in accordance with the project specifications.
2. All loose materials will be removed from the duct before the start of cable pulling.
3. Approved cable pulling lubricant will be used while cable pulling in to the duct banks or UPVC/HDPE
conduit if required.
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4. Before pulling operations begin a communications link will be established between the feed and pull
manholes (and any intermediate manholes the cable may pass through).
5. Once the cable appears in the pull manhole it may be pulled over a sheave or quadrant block as long as
the diameter of the sheave or block meets the cable’s minimum bend radius under tension. No attempt
should be made to inch the cable to its final manhole. This may cause undesirable surges to the end
portion of the cable.
6. It is ensured that the manufacturer’s recommendations for installation of cable pulling are done by
proper tools, pulling winch, and concrete protection from mechanical stress.
7. Cable identification tag will be provided on cables at each entry and exit point of the buried duct and in
other such positions to identify and trace the route of the cable.
8. Ducts including spare ducts will be sealed at the point of entry or exit by approved sealant materials after
installation of all cables.
3. CABLE BACK FEEDING PROCEDURE
1. Identify the inner duct in which the ELV cable is to be placed. After the correct inner duct has been
identified, it will be tied off to keep it from “creeping” as the cable is being pulled into it. Any spare ducts
should be capped off so that they do not interfere with the cable pulling operation.
2. When pulling problems are expected due to long duct lengths, excessive curvatures in the duct, or for
other reasons, the cable can be pulled in from two directions.
3. Attach the pulling line to the cable and position the reel in the same manner as for an end pull.
4. The pull manhole setup and the feed manhole setup are the same as they were for an end pull.
5. Communication, lubrication, and cable pulling are all conducted as for an end pull as show below
6. Before pulling operations begin a communications link will be established between the feed and pull
manholes (and any intermediate manholes the cable may pass through).
7. (If required) At the mid-feed manhole, remove the remaining ELV cable from the reel. The cable will be
laid out in a large figure-eight configuration close to the manhole opening. Keep the cable as clean of
debris as possible by not figure-eight the cable onto sand or dirt which might adhere to the cable. Sand
or dirt clinging to the cable will cause increased pulling tensions. Spreading out a sheet of polyethylene
before beginning to figure-eight is one method that will help keep the cable reasonably clean.
UNDERGROUND WARNING TAPE
1. The 100mm wide warning tape, detectable type, colored yellow with suitable warning legend
describing buried ELV lines. Avoid sharp bends and narrow loops.
2. Identify underground conduits using underground warning tape. Install one tape per trench at 150mm
below the finished grade.
3. It is ensured to implement all points required by HSE and environments and sustainability before
starting the work on site.
4. Throughout the duct bank execution stage and upon completion, representatives from the Engineer will
be invited to carry out inspections of the works.
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 801 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
5. The contractor will be ensured that his program works are in the designated sequence in accordance
with the approved program
6. Completion of each phase of the works to progress to the next phase will be subject to the approval of
the Engineer.
PREPARATIONS FOR BACKFILLING
1. Before the commencement of any work at the site, the Site Engineer/Supervisor and H & S officer will
instruct the field team regarding work method and safety measures in line with the subject method
statement.
2. Safety barriers will be placed on existing structures, services within defined the working zone before and
during activities at the site. Sensitive areas will be marked out within or adjacent to works with signage.
3. For safe operations, all personnel not directly involved with the operations will be kept clear of the
working area. A demarcated observation area will be established to enable safe monitoring and
observation of the works without encroaching into the working zone.
4. All personnel needing to enter the working area will need to first inform the available
foreman/supervisor in charge of the operation and ensured that prior to entering the works, the flagman
is alerted.
5. Proper lighting will be supplied at the site during night work. Flagman will be aware of blind spots of
vehicles and all workers will be provided Reflective Jackets along with necessary PPE.
6. Necessary dust control and noise reduction measures will be carried out.
7. The safe observation area will be established at the site covering with safe barricades.
8. Movement of vehicles or machinery, temporary stockpiling of soil at the observation site’ will be
restricted.
4. REDLINE MARK-UP & AS-BUILT
If any changes occur in the cable routes (Non-adherence to the approved shop drawings) then such
information will be detailed in the As-Built Drawings with Red Lines.
5. TESTING AND COMMISSIONING METHOD STATEMENT FOR ELV
A detailed separate electrical method statement for system testing & commissioning of the ELV
system has to be developed and submitted.
6. QUALITY PROCEDURE OF METHOD STATEMENT FOR ELV
The Inspection and Test Plan (ITP) for this Method Statement for ELV (Extra Low Voltage)
system summarizes various characteristics to be checked. The concerned Site Engineer or Site Supervisor
will be responsible to ensure compliance for these operations and the site QA QC ELV Engineer will carry
out quality control checks and report the inspection results.
7. QUALITY RECORDS
1. Quality records will be provided as identified in the ITP and maintained as per ISO 9001/Project
Requirements and Specifications.
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CONTRACTOR
NAME:
2. The standard form of records, quality checklists, and QA/QC reports requirements are defined in the
Inspection and Test Plans.
3. Submission of as-built records will be done after completion.
8. SPECIFIC QUALITY MEASUREMENTS
1. All works will be undertaken in compliance with the quality requirements of the Contract and “Project
Quality Management Plan”. Where non-conformances are found /identified to demonstrate its
conformity. All works requiring inspection and system testing to demonstrate conformity with
requirements will be undertaken in accordance with the “Control of Inspection and Testing”.
2. Where non-conformities are found/identified, they will be addressed in accordance with “Procedure for
Control of Non-Conformances”. The quality control activities associated with the works will be conveyed
to all personnel involved in the execution of the works by the Project QA/QC Manager prior to the
commencement of the work.
3. The equipment and instruments widely used for measurements on-site will be calibrated and certified.
The relevant project documentation will accompany the corresponding equipment and instruments.
Necessary internal and external training is provided to the staff carrying out the job to ensure that the
quality standards required on the project are met. Skilled and competent personnel are deployed to
undertake the job.
9. HEALTH AND SAFETY PLAN OF METHOD STATEMENT FOR ELV SYSTEM
Site safety control shall be conducted in accordance with the guidelines stipulated in the attached Risk
Assessment.
1. To ensure that the permit system should be followed according to the HSE Plan
2. To ensure that the lifting operation should be followed according to the HSE Plan
3. Copies of 3rd party certificate, drivers/operator’s license vehicle’s registration, and security pass to be
submitted to Company safety department before commencing the work.
PERSONAL PROTECTIVE PPE REQUIREMENTS
PPE is the last line of defence not the first: however, every contractor should provide adequate suitable,
sufficient PPE to protect the workforce wherever possible. As a minimum for all personal during the
abutment works will be hat, safety boots, coveralls, goggles and gloves will be provided and used at all
times. Additional task specific PPE will be provided and worn in line with risk assessments.
EMERGENCY RESPONSE
Emergency response shall be initiated by Authorized Person. Emergency response section in HSE plan
shall be followed
In case of an emergency the following actions shall be activated:
Stop the activity
Call the emergency number for help
Provide first aid and call the ambulance
Alert site clinic / Nurse/ First aider
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CONTRACTOR
NAME:
10.RESPONSIBILITIES
PROJECT MANAGER
1. The Project Manager (MEP) will be responsible to manage, execute, complete, and handover the
construction activities within approved budgets and resources in compliance with Project Requirements
as specified in Project Specifications. He will be overall in charge of implementing the Method Statement
for ELV in accordance with QA/QC and HSE requirements.
2. Responsible for controlling the project’s entire activities & for the overall coordination with the
consultant/client.
3. Ensured that adequate welfare facilities and equipment are provided to the project to avoid injury,
health impairment, or damage & provided quality works within the planned time scale.
4. All responsibilities stated in the Project’s Quality Assurance Plan.
CONSTRUCTION MANAGER
1. Organize the site so that work is carried out to the required specifications with minimum risk to men,
equipment, and materials.
2. Coordination with different functions with the project.
3. Expediting area of concern to achieve project schedule.
4. Adhere to the project-specific quality management program and HSE requirements.
5. Delivering the overall works in a safe and timely manner, ensuring conformance with the approved
design. Leading the team of engineers and surveyors, guiding them in the delivery of the works. Acquire,
allocate, and maintain resources.
QA/QC MANAGER
1. Responsible for the work entire quality assurance, quality control & inspection programs
2. Produce all quality-related documents & reports necessary as requested by the
Client/Consultant/Engineer.
3. Provide written procedures & to coordinate in formalizing the Method Statements for ELV with the
Project Manager/ Construction Managers/Site Engineers to describe the job-specific work for each
stage/activity.
4. All responsibilities stated in the Project’s Quality Assurance Plan.
QA/QC ENGINEER
1. Responsible for the work of entire Quality Assurance, Quality Control & inspection programs.
2. Produce all Quality related documents & necessary quality reports as requested.
3. Provide written procedures & to coordinate in formalizing the Method Statements for ELV with the
Construction Manager/Site Engineers to describe the job-specific work for each stage/activity.
SAFETY MANAGER
1. Manage Safety Engineers and Safety Officers to be in strict conformance with project policies and
procedures.
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NAME:
2. Ensure the safe work method stated in Method Statement for ELV is fully implemented during
activity.
3. Responsible for controlling HSE personnel for effective monitoring of work.
4. Over-see site safety orientations/inductions, toolbox talks, safety training certifications, job site
inspections, working at heights, scaffolding tagging systems are fully functional, rigging, etc.
5. Report to Project Manager all personal injuries and near-miss incidents (aligned with Safety
Engineers / Officers) as well as property damages immediately. Produce investigative reports and
summaries to senior management.
SAFETY OFFICER
1. Provide advice and coordination in line with the project HSE Plan, legislation, and standards in Qatar to
workgroups as required/directed.
2. Input into the preparation and maintenance Risk Register at the project level which will form the basis of
risk management on the project.
3. Monitoring and reporting compliance with the project HSE Plan
4. Assist with the implementation and monitoring of the project.
5. Conducting regular HSE inspections and participating in HSE audits.
6. Reporting as required, HSE incidents, including near-miss events, injuries, and any other HSE issues.
SITE ENGINEER
1. Adheres to the Project-specific method statements, procedures, inspection programs & HSE instructions
to get the activities performed to Client satisfaction with full coordination with the HSE & Quality
personnel. Responsible for ensuring that correct drawings, materials, tools, and equipment are
provided on-site.
2. Liaising with sub-contractors, supervisors, planners, quantity surveyors Send the general workforce
involved in the project.
3. Responsible for planning the work and efficiently organizing the plan and site facilities in order to meet
agreed deadlines.
4. Site engineer is responsible to coordinate with QA/QC team engineers/ inspectors, and for the handover
of daily site, progress works report/highlighted drawings & present during the inspection/site visit with
QA/QC Inspectors & consultant/client.
SURVEYOR
1. Will be responsible for all survey work and will report to the chief surveyor.
GENERAL FOREMAN
1. Performed the activities instructed by the Supervisor/Engineer at the site and follow the safety
procedures to make it safe for his workers.
2. In charged to lead the work execution to send the focal point in coordinating with site
3. Supervisor/Engineer is related to overall site activity, materials, tools, and equipment.
TECHNICIAN
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1. Carry out installation work as per the concerned foreman’s instructions with all the safety requirements.
2. The workforce to attend daily toolbox talks, morning task brief briefs prior to starting any works EHS
(Environment Health Standard) plans and policies.
3. Must have a certain amount of experience and expertise that is required when working with high-tech
network and security equipment.
WORKFORCE
1. Supervisor
2. Foreman
3. Charge Hand/Supervisor
4. HSE Engineer/officer
5. Surveyor
6. Plumber
7. Skilled Labour as per the required work
11.TOOLS AND EQUIPMENT’S
The operator of the equipment will be certified by a third party and have a valid license/ registration
issued by the traffic department.
Spanner Set
Screwdriver set
Marker/whitener & lined
Wooden hammer
Metal cutting saw
Mobile scaffolds
Grinder
Drilling machine
Manlift
Spirit level
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CONTRACTOR
NAME:
METHOD STATEMENT FOR
WATERPROOFING
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CONTRACTOR
NAME:
SR. EFFECTIVE REV. MSS MANAGER MSS PROJECT CLIENT
CLIENT QA/QC
NO. DATE NO. QA/QC MANAGER SUPERVISOR
WATERPROOFING
1. PURPOSE
The method statement for waterproofing is the work procedures and means of controlling specific health
and safety risks involved in installing the waterproofing system composed of keyed pre-formed sheet
waterproofing applied below the base slabs and sides of the base slab for concrete structures like tunnels,
car parks and other structures followed by the application of liquid polymer spray waterproofing
membrane.
Waterproofing is the process of forming an impervious barrier to control all water from penetrating a
material, including soil moisture, water vapor, and liquid water that is under hydrostatic pressure or
specified conditions.
2. OBJECTIVES
The objective of this method statement is to describe the sequence of operations and means of
controlling specific health and safety risks involve in waterproofing system including a keyed pre-formed
sheet waterproofing system to below the base slabs and up both sides of the base slab of concrete
structures like tunnels, car parks, and buildings followed by application of liquid polymer spray
waterproofing membrane to structural concrete work other than base slab structures.
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MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
The waterproofing work is basically divided into two phases:
a. Phase – 1: Installation of PVC T-Lock (Keyed Preformed Membrane–KPM)
b. Phase – 2: Application of Liquid Polymer Spray Waterproofing Membrane
3. DEFINITIONS
xxxx Company / Client
xxxx Project Management
xxxx Supervising Consultant
xxxx Sub-Contractor
SE Site Engineer
QC Quality Control Engineer
SF Site Foreman
PM Project Manager
SA Site Agent representative from the Lab
HSE Manager Health, Safety & Environmental Manager
HSE Officer Health, Safety & Environmental Officer
xxxx Main Contractor
GIS Geographical Information System
PS Project Specifications
CEMP Construction Environmental Management Plan
QCP Quality Control Plan
HSE Plan Health, Safety and Environment Plan
GWL Ground Water Level (meter)
NGL Natural Ground Level (meter)
Note: All dimensions are in mm unless specified.
4. REFERENCE
Project Specifications–Protective Treatment for Concrete
Health and Safety Plan, ref.: xxxxxx
CEMP, ref.: xxxxxxxxx
General Lifting Plan – ref.:xxxxx
Baseline Schedule- Detailed, ref. no.: xxxxxx
Material Submittal for Waterproofing System, ref. no.: xxxxxx
Method Statement for Concrete Works, ref. no.: xxxxxxx
Waterproofing Shop Drawings, ref.: xxxxx
This Method Statement shall be read in conjunction with the following Standards, Plans and Documents;
Project Drawings
Logistics Plan
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NAME:
Health & Safety Plan
Other Relevant Procedures
Manufacturer’s Instructions
5. RESPONSIBILITIES
PROJECT MANAGER
Supervise closely, the activities designated to them and ensure that all instructions and safety procedures
are followed and strictly adhered to.
Supervise the work to ensure that technical, quality, safety and purchase order requirements are met;
Attend daily site meeting and communicate his daily report with the Project/Site Engineer; Participate in
training and development of his subordinates; Organize with the Project/Site Engineer to ensure the
availability of plant, equipment, and labor to his designated work activities; Closely monitor the usage of
consumable and materials by his crew in order to minimize wastage; Assess craftsmanship of
subordinates under his control.
CONSTRUCTION MANAGER
Carry out pre-construction survey to fix the locations and corresponding elevations as per the approved
shop drawings.
Ensure the quality and compliance during phases of surveying works and the regular checking of the
surveying equipment or periodic calibration from third party.
Ensure validity and serial number of calibration certificates is available and posted in the survey
equipment.
Ensure proper safety guarding of surveying equipment.
To maintain the records of all surveying equipment handled.
SITE ENGINEER
Supervise operations in accordance with the approved method statement for waterproofing, shop
drawings, specifications, material submittals and schedules to achieve the acceptance of the project
deliverables.
SITE SUPERVISOR
Supervise closely, the activities designated to them and ensure that all instructions and safety procedure
are followed and strictly adhered to.
Supervise the work to ensure that technical, quality, safety and purchase order requirements are met;
Attend daily site meeting and communicate his daily report with the Project/Site Engineer; Participate in
training and development of his subordinates; Organize with the
Project/Site Engineer to ensure the availability of plant, equipment and labour to his designated work
activities; Closely monitor the usage of consumable and materials by his crew in order to minimize
wastage; Assess craftsmanship of subordinates under his control.
CHIEF SURVEYOR /LAND SURVEYOR
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Carry out pre-construction survey to fix the locations and corresponding elevations as per the approved
shop drawings.
Ensure the quality and compliance during phases of surveying works and the regular checking of the
surveying equipment or periodic calibration from third party.
Ensure validity and serial number of calibration certificates is available and posted in the survey
equipment.
Ensure proper safety guarding of surveying equipment.
To maintain the records of all surveying equipment handled.
SURVEY AIDE
Maintain and use Surveying equipment. Assist Surveyors in taking measurements, record measurements
manually or electronically, and peg out boundaries.
HSE MANAGER
Health, safety and environmental (HSE) manager generally plan, coordinate and implement issues and
directives within the organization.
They ensure safe environmental working conditions for all employees.
HSE ENGINEER
Ensure enforcement of safety procedures in accordance with the approved HSE Plan.
Will be closely monitoring the site engineer’s strict implementation of the MS and Risk Assessment, the
use of proper tools and equipment to maintain safety, certifications of equipment and their adherence to
safety regulations, reporting of any unsafe work or stopping work that does not comply with ES&H
procedures.
ENVIRONMENTAL OFFICER
Report to HSE Manager. Ensure enforcement of environmental procedures in accordance with the
approved HSE Plan. Will closely monitor implementation of MS and Risk Assessment, the proper storage
and handling of materials. Report any breaches of regulations and stop work if required to get compliance
with ES and H procedures.
LIFTING COMPETENT PERSON
The role of the Lifting Competent Person is to ensure compliance to safe practice for the loading and
unloading of equipment and materials on site.
FIRST AIDER
The first aider respond promptly when requested, operate with competence, know how to secure
additional help when needed, reports incidents and actions taken and comply with requirements for
certification.
BANKSMAN
The role of a banks-man is to provide additional eyes and ears to assist the operator of the equipment to
navigate or operate safely.
6. INTERFACING WITH OTHER OPERATIONS
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NAME:
For Phase – 1: Surface preparation of RC Base Slab and installation of reinforcement
For Phase – 2: Completion of Reinforced Concrete Works with required embedment
7. DURATION, PHASING WITH THE SUBCONTRACTORS
Refer to approved base line schedule for duration of waterproofing works. Ref.: xxxx
8. LIST OF SUBCONTRACTORS
Subcontractor
As per approved Subcontractor-xxxxxxx
9. RESOURCES
1. PLANT AND EQUIPMENT
Description No. of Units Application
Leister Varimat Welding Machine 3 Hot Air Welding of T-Lock
Leister Triac S Welding Machine 10 Hot Air Welding of T-Lock
Air Compressor 2 Spray Membrane
Weather Station Instrument 1 Testing Environment
Hydracat Dual – Component Airless Spray 2 Spray Membrane
2. WORK FORCE
Designation No. of Persons
Site Engineer 1
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NAME:
Site Supervisor 2
Waterproofing Technicians 8
Waterproofing Assistants 16
QA/QC Engineer 1
HSE Engineer 1
First Aider 2
3. LIGHT TOOLS
Description No. of Units Application
Pressure Rollers 10 Application of Jointing
Holiday Test Machine 1 Testing Membrane
Positester Defelsko Machine 1 Testing Membrane
Small Hand Tools As per site requirement Cutting, Testing
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NAME:
Elcometer 106 tester 1 Check the concrete surface
10.MATERIALS
These are only for example of material brands)
Euroseal PVC T-Lock (Keyed Preformed Membrane– KPM)
Internal and External Waterstop – Type 3
Injection Hose
Swelling Bar
Integritank Spray Membrane- Liquid Polymer Spray Waterproofing (Part A & B)
PA1 Primer
Metaset Structural Adhesive
Debonding Tapes and Reinforcement Scrim
PVC Flat Strip (2.0mm)
PVC Dilation Tape (2.0mm)
Note:
Test Certificates – Applicable. Please refer to submitted Material Submittal for Waterproofing System, ref.
no.: xxxxx
11. SITE PLANNING
Refer to approved Baseline Schedule- Detailed, ref. no.: xxxxx for the initially planned duration of works.
However, the duration can be indeterminate but not critically affecting the program of works.
PREPARATION
a. Permits from the concerned authority shall be obtained prior to start work at the site.
b. The contractor shall ensure that all gate passes, permits, tools, materials for safety precautions,
manpower, and equipment are available before the commencement of work.
c. The Site Team shall make sure that access roads are always clear from any obstruction and site is always
accessible.
d. Organization Chart of is attached in Appendix – L.
SITE CLEARANCE
Before commencing the work, the area shall be cleared of all debris, materials, or other obstructions.
TRAFFIC MANAGEMENT
a. The Site Team with the assistance of the Safety Officers shall coordinate logistics and materials
movement through site following the direction and road signs displayed on site. The required diversion
routes shall be marked on drawings including the required traffic signs.
b. The Work Permits and Operator Certificates shall be compiled and files for reference by authorized
personnel.
PRE-CONSTRUCTION SAFETY MEETINGS
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The meeting shall be scheduled prior to the beginning of the work and before any Subcontractor starts
on the project.
a. General contractual safety, health and environmental requirements.
b. Depending upon the phase of waterproofing works, safety concerning to electrical, working at height,
working with chemicals etc. shall be discussed to emphasize these meetings.
c. Roles of the contractor, subcontractors, authority representatives, and all project workers.
d. Accident reporting requirements.
e. Specific details of the work to be performed along with the use of personal protective equipment.
f. Emergency procedure.
12.PROCEDURE-METHOD STATEMENT FOR WATERPROOFING SYSTEM
Waterproofing System is divided into two phases which are the application of PVC T-Lock:
Membrane and application of Integritank spray membrane. The T-Lock Keyed Pre-formed Membrane
(KPM) membrane is applied before the concrete work start and Spray membrane is applied after the
concrete has attained the required criteria for the application. The contractor shall execute the trial test
section on the vertical and horizontal surface which shall include details of construction and expansion
joint, complete with protection system and approval before application to the structure.
Subcontractor team at the site shall be responsible to check all items of waterproofing system against the
sequence of construction starting from laying of reinforcement bars for base slab till the finishing of
backfilling, considering the following:
a. Subcontractor to arrange for 24/7 supervision responsible representative at the site for Backfilling
surveillance, installation of protection board, and waterproofing repairs as required.
b. The subcontractor to provide the Specific Organization Chart of the Supervision Team for the project.
c. The subcontractor to sign a separate checklist as attached in Appendix F to check the waterproofing
membrane during the backfilling work application.
V.1 Phase – 1: Application of Keyed Pre-formed Membrane (PVC T-Lock)
V.1.1 Installation of Keyed Pre-formed Membrane (KPM) to Base Slab
1. Blinding concrete to be smooth and even finish with no sharp projections or abrupt steps, clean and
free of loose stones or debris.
2. Blinding concrete surface condition and area for laying membrane to be agreed with Main Contractor,
Consultant, and subcontractor site in charge.
3. Unroll the KPM across the floor so that the keys are aligned transversely to the longest dimension of
the structure.
4. Where the KPM will be continued up the wall, cut the strip to the appropriate length to provide an
upturn to the edge forms. The upturn must be of sufficient length (500mm vertical minimum and for
practical reason can be extended up to 1000mm) to allow connection to the external waterproofing. Refer
to Typical Drawing ref. no. xxx. Fix top of the membrane to formwork by staples. Apply sealant to the top
of the membrane to avoid grout runs behind the membrane.
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5 .Where the lengths of the membrane (i.e. parallel to the keys) have to be joined longitudinally,
overlap the edges of the sheets, and use an automatic welding machine, hot air gun, and pressure
roller to provide a welded joint. The welded single seam will be a minimum of 30 mm wide minimum.
Where sheets of membrane need to be joined end on end then cut back the keys of both sheets from
the end of each sheet for 80 mm width, overlap sheets, and weld sheets together. Reweld keys back
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into position. Refer to Typical Drawing ref. no. xxxxxxx. Apply Integritank Liquid Membrane and
Metaset Adhesive to keys of joint as added protection.
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6. At the intersection between the base and the side form, install a 25 mm x 25 mm prefabricated angle
fillet to allow T-Lock Membrane to be upturn against the form face so that keys do not need to be cut.
Refer to Typical Drawing ref. no. xxxxxx.
7. Refer to approved Shop Drawing for T-Lock folding and terminations to structural concrete ref. no.
xxxxx. However, PVC T-Lock upturn should be discussed at the site prior to fixing as per drawing notes.
Additional layer thickness is to be added at turns bends and edges as reinforcement, especially
underneath portions.
8. Heating temperature and method of welding to be in accordance with T-Lock manufacturer’s training
and ambient temperatures.
9. Where external waterstop is to be installed at expansion joints, cut off the T’s (using a sharp blade) and
weld the waterstop with a hot air gun and pressure roller at both sides of waterstop minimum of 20 mm,
leaving center part not welded. Refer to Typical Drawing ref. no. xxxxx
10. Internal waterstop will be installed at a specified height as shown on approved reinforcement detailed
drawing using best management practice.
13.INSPECTION AND TESTING (KPM)
1. A site trial (mock-up) will be carried out to demonstrate the welding and inspection procedures.
2. For single seam welds, visually inspect seam for discontinuity and run screwdriver blade along the seam
to check for discontinuity. Visually check that melted PVC has bled out evenly along the welded joint.
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3. Spark test all the seams with a holiday/pinhole detector with the direct current voltage set for 4mm
thick membrane (two layers) and not exceeding the material’s dielectric strength. (Note all the
overlapped seam weld be tested 100%). (Refer to the photo below).
4. Welding of external waterstop to T-Membrane will not be tested as it is used to keep the waterstop in
place only.
5. If the voltage is set to 10,000 V, ensure that only overlapped seam welds are brushed with the sensor.
The membrane thickness will be 4mm because of the overlap. This voltage shall not be used on the 2mm
thick membrane because of the danger of burning pinholes.
6. Safety precautions (trained operatives, exclusion zone, and equipment safety cables inspection) are to
be observed when using high voltage testing equipment. The spark tester is not to be used in wet
conditions, where reinforcing steel is fixed or where danger from explosion exists.
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7. The membrane shall be inspected for damage as a hold point after the bottom layer of reinforcement
has been completed.
14.REMEDIAL WORK TO KPM
1. Prior to concreting, any extensively damaged KPM will be cut out to the nearest adjacent welded seams
and a new strip of membrane fitted, joined by single seam welding with 30 mm weld. The repair area will
be tested by running a flat-headed screwdriver along the welded joints to see any missed weld.
Note: Subcontractor will monitor the rebar installation on the base slab and will repair any damage as it
occurs or is first noted.
2. Small splits, tears puncture, or tie bolt holes may be sealed by hot welding a patch of KPM with an
overlap of at least 30 mm. (Refer to the photo below).
3. Punctures caused by nailing or such must be sealed by hot welding a patch 50 mm diameter or 50 mm
square over the puncture hole.
4. Repairs to the T-Lock membrane cannot be inspected by high voltage spark testing when the
reinforcement has been placed as there is a safety concern for the operator. In such cases, physical
checking with a flat-headed screwdriver shall only be carried out.
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15.CONCRETE SPACER BLOCKS
1. Concrete spacer blocks should fit between keys of T-Lock and should have dimensions 100 mm x 50
mm.
2. Spacer blocks to be staggered.
3. The maximum spacing of spacer blocks shall be as referred to in approved shop drawings.
V.2 Phase – 2: Application of Integritank Spray Membrane
V.2.1 Preparation of Concrete Substrate
1. All concrete deck shall, where necessary, be prepared by suitable mechanical means such as diamond
grinding, vacuum blasting, or grit blasting to provide a sound surface free from laitance.
2. Concrete surface to receive Integritank should be a minimum of 14 days old or should achieve 0.7 MPa
pull off value as described below. All defects on the surface of concrete and dry cracks should be
repaired to the satisfaction of the approved applicator of the waterproofing. Refer to Application
Guidelines of Integritank, attached.
3. Horizontal surfaces to be U4 finish, the vertical surface will be formed finish. Ensure that there are no
sharp projections or tie wires, clip off any nails. Blowholes are to be filled with an epoxy mortar approved
by the approved applicator of the waterproofing.
4. Before the Integritank is applied, the surface condition of the concrete will be checked to ensure that
the adhesive bond will be achieved. The adhesion of the membrane to the concrete surface will be
checked by the use of Positest Defelsko. Place a 50 mm diameter dolly every 50 m² coated in fresh
Integritank onto the concrete surface to be tested. Allow the Integritank to cure for at least 4 hours and
then pull the dolly off the concrete using the Positest Pull-off tester and note the pull off value measured.
5. If tensile adhesion tests as described above fail to achieve 0.7 MPa and the failure mode is in laitance
then surface laitance may be removed by light shot blasting or grinding. If the failure is less than 0.7 MPa
and the failure mode is in the concrete substrate then accept the value of pull off as the concrete surface
strength.
Note: If the tensile adhesion test is less than the required value, the main contractor must prepare the
surface to achieve the value by light sandblasting or grinding.
6. Following preparation work, perform a joint inspection (INR) with the Engineer/Main
Contractor/Waterproofing Subcontractor to ensure the surface is fit to proceed with membrane
application.
7. The concrete surface is to be checked to be touch dry before the application begins. Check that
substrate temperature is at least 3 °C above dew point temperature. Check dew point temperature before
the commencement of the spray membrane and at the start of every work shift.
8. In case of doubt, check the surface with a dry tissue paper. If there is no moisture pick-up, the surface
moisture condition is suitable. Before the application of primer, blow down the concrete substrate by
compressed air to remove dirt and dust. Concrete surface moisture checking shall be done at the site
before the application of the spray membrane.
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9. The spray team shall not apply the membrane if the wind speed is too high which shall cause overspray
and/or loss of material. Spray team shall also not apply membrane if the wind has airborne dust and dirt
that will contaminate the spray membrane. Confirming to the proper training of the spray team,
measuring, and understanding of wind speed or dust contamination in the air is not necessary. Trained
spray teams are experienced enough to stop and resume work depending upon weather conditions.
10. The subcontractor and main contractor shall carry out the surface moisture content test through a
third-party lab. It shall be done only once but before starting actual work. This can be carried out on
mockup also.
16.APPLICATION OF INTEGRITANK
1. Integritank will be applied as a 2.0 mm minimum thick coating in two coats.
2. Wet film thickness checks of the sprayed membrane measured prior to the Integritank setting to be
taken every 2 m² manually by the sprayer using a wet film gauge. The target thickness is 1.2 mm on each
coat. The target overall consumption rates for per coating is 1.4 kg/m². All records for the consumption
will be recorded in QA/QC forms. Spray supervisor to check the wind and airborne conditions on site
before commencement of work to either protect the work substrate or abandon the work until more
favorable conditions are available.
3. Mask any furniture or surfaces not to be coated to protect from overspray. Prepare boundaries with a
straight edge formed with masking tape and remove the masking tape before the membrane starts to gel.
The surface of the prepared concrete will be primed using spray or roller applied PA1 primer at a rate of
approximately 0.2 ± 0.05 kg/ m². Allow the primer to cure until tack free, normally approx. 30 minutes
4. Depending on temperature add 6kg-8kg of hardener powder (Di-benzyl peroxide) into 192 kg drum of
Integritank Part B either yellow or grey and mix thoroughly with the air driven mixer. Once the catalyst
has been added the Part B becomes active. To avoid any problems it should ideally be used the same day.
The typical Pot Life of a 24 kg bucket of Integritank Part B containing the catalyst in the temperature range
of 10°C-40°C is as follows:
Pot Life (Standard catalyst
Temperature (°C)
addition)
40 16 hours
30 50 hours
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23 16 days
12 (Average Temperature) Not cured after 80 days
5. Mix Part A thoroughly before use with the air driven mixer.
6. Attach Integritank Part A and Part B to Hydracat pump for spraying in equal proportions.
7. The equipment is a plural component pump, metering Part – A & Part – B on a 1 to 1 ratio by volume
mixing in line and delivering the mixture by airless spray.
8. The applicator shall be skilled and experienced and shall be able to spray the coating according to good
practice. The applicator will ensure that the coating will be applied in a uniform manner, with overlap
(approx. 150 mm) at the edges of the spray pattern. The applicator should monitor the process and his
technique by regular visual checks and wet film thickness checks of the freshly applied coating.
9. Spray apply Integritank yellow coat at the rate of approximately 1.4 kg/m² to achieve a target wet film
thickness of 1.2 mm (equal to the dry film thickness of more than 1.0 mm). Allow curing for a minimum of
30 minutes.
10. Inspect the yellow coat for visible holidays and misses and snag as necessary with hand mixed
Integritank yellow coat.
11. Same procedure will be applied for the 2nd coat which is grey in color.
12.Note: Part B material is pigmented either yellow or grey as a visual aid to achieving full coverage. There
are no detrimental effects of applying grey on grey or yellow on yellow providing the 2mm thickness is
achieved.
17.APPLICATION OF INTEGRITANK AT DAY JOINTS
1. Spray Integritank to a convenient termination to a straight edge formed with masking tape to each
component (Primer & yellow coat to be stepped back 50 mm) to allow overcoating of each layer.
Remove tape immediately after spraying the coating to avoid any fretting. When overcoating, bring the
fresh Integritank over the existing to form a 50 mm overlap to each layer.
18.TREATMENT OF CONSTRUCTION JOINT (REFER TO V.3.3.1 & V.3.4.1)
1. For construction joints where there is no external Waterstop, apply stripe coat of 0.5mm thickness of
Integritank membrane over the debonding tape over a width of 180mm (90 mm either side of the
construction joint). Bed in the reinforcement scrim (175 mm width) while the stripe coat is still liquid.
Once the scrim is embedded the normal 2 coats Integritank 2 mm membrane can be applied over the
whole surface.
2. Add 2mm PVC Flat Strip (200 mm wide) membrane over the Integritank and fixed to the spray
membrane by Metaset adhesive. Apply further Metaset adhesive to the top face of the PVC Strip and
apply 2mm Integritank membrane leaving center part of PVC Strip not sprayed.
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19.APPLICATION OF INTEGRITANK TO INTERFACE AREA OF T-LOCK MEMBRANE
1. Repair all fish lips and broken edges with epoxy. Remove all nails grind off shape edges and use light
brush grinding or sandpaper on the surface of T-lock where Integritank will overlap. Clean the surface of
the T-lock membrane longitudinally (200mm wide) Apply Metaset Structural adhesive by using the brush
at approx. 1Kg /m² coverage. Wait until adhesive becomes tack free then apply Integritank system. Bond
testing may be done in this location if instructed.
19.APPLICATION OF INTEGRITANK OF EXPANSION JOINT ON WALL AND ROOF
1. (Refer to V.3.1, V.3.2 & V.3.3)
FOR WALLS
1. Repair both sides of the waterstop for any fish lips and broken edges with epoxy. Remove all nails and
grind off sharp corners.
2. Fix 50 mm wide masking tape vertically on to the center of external waterstop.
3. Apply Metaset Structural adhesive by brush. Wait until adhesive becomes tack free then spray
Integritank system on top of external waterstop.
4. Remove the masking tape. Once the liquid is dry apply Metaset Structural adhesive on both edges of
waterstop where Integritank is sprayed earlier and carefully fix the PVC sheet membrane.
5. Spray Integritank on both sides of PVC sheet membrane leaving center part not
sprayed. (Refer to Detailed Shop Drawing ref. no: xxxx. Bond testing may be done in this location if
instructed.
FOR ROOF
1. Adhere 2 mm PVC dilation tape to concrete to cover the expansion joint except over the de-bonding
tape on the concrete.
2. Apply Metaset Adhesive to top of dilation tape and place a 2 mm PVC flat strip over the joint. Apply a
de-bonding tape over the center section of the PVC Flat Strip.
3. Apply Metaset adhesive over the PVC flat strip and apply the 2 mm Integritank membrane. Remove
the de-bonding tape.
REPAIR AND REPLACEMENT OF INTEGRITANK
If any damage or defect occurs, such as blisters, misses, or large pinholes, it will be repaired as follows:
1. Grind or sand the edges of the broken membrane and clean the surrounding area with MEK solvent or
acetone solvent.
2. Using a small scraper, hand mix equal proportions of catalyzed Integritank Part B with Integritank Part A
until completely blended.
3. Apply the new membrane with a spreader or scraper to replace the removed membrane and extend
the application to a 20-30 mm overlap in each direction. A 2.0 mm layer may be applied in one operation.
4. For larger areas of damage, or a complete replacement, it is necessary to remove the Integritank from
the substrate. Mark out the repair area into a square or rectangular shape. Cut through the membrane
along the perimeter of the repair area to establish a neat edge. Due to the tenacious bond of the
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membrane to the concrete substrate this membrane removal can only be done by mechanical means –
grinding and shot blasting.
5. If some residual Integritank inside the repair area cannot be easily removed from the substrate it is
acceptable to allow it to remain, providing it is fully bonded.
6. Prime surface with PA-1 primer and spray Integritank in two coats, as described in this method
statement.
7. Pinhole and blowholes shall be filled with SIKADUR 31 SLOW or CONCRESSIVE 2200 BASF (or
equivalent). Cracks and surface undulations or surface-level mismatch of the concrete surface shall be
filled/levelled with approved epoxy mortar.
QUALITY ASSURANCE
1. The maximum substrate temperature for Integritank spray membrane is 50ºC. However, work shall be
limited to be done at ambient temperatures of 40ºC for workers’ comfort. In summer months work shall
be done after sundown. The Elcometer Weather Station Machine available on site calculates dew point
temperature. This machine records ambient temperature, substrate temperature, and relative humidity
to get a dew point temperature.
2. Measure the deck surface temperature. Record the measurements on the proforma. The Integritank
Membrane shall be applied at substrate temperatures at least 3ºC above Dew Point temperature to avoid
surface moisture. The internal concrete moisture level is of no importance for Integritank. It is only the
surface dryness that dictates the proceeding of the Integritank spray work. The concrete surface should
be touch dry tested by hand or with a paper tissue to check for dryness. The equipment to measure the
dew point shall be calibrated.
3. Record the batch numbers of all materials used. Record the weight of Integritank consumed for
weight/thickness reconciliation. This information is to be recorded on the daily inspection proforma.
4. Coating application by airless spray is a special process that relies on the skill and experience of the
applicator. The applicator will monitor his performance and thickness of the sprayed coat by regular
dipping with a wet film thickness gauge.
5. The following application and snagging, check for pinholes and holidays using a high voltage
discontinuity tester. The area will be checked with a high voltage spark detector, with the voltage set
between 8,000 – 10,000 volts.
6. Adhesive Bond Test and Dry Film Thickness (DFT) Test of Integritank spray membrane shall be carried
out for the final layer. The test frequency for the simultaneous bond test and DFT test shall be at every
100 m² or as directed by the engineer.
7. Wet film thickness checks on each coat of Integritank shall be carried out at a frequency of 1 per 2 m².
The coating shall be done by the sprayer so if an area is having less than 1 mm thick the same can be
sprayed more and shall be rechecked.
8. The dry film testing is done on the finished membrane by a destructive cutout and direct measurement
with calipers. This dry film thickness testing is usually done at the same location as the membrane post-
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application Pull off testing to limit the destruction to the finished membrane. The relationship between
NDT and DT for checking the thickness of the film shall be established on-site during mock-up. Depending
on the result and its agreement with all parties, the further tests shall be conducted for checking of spray
thickness.
9. All required quality control tests for each application of the system to be carried out according to the
approved schedule plan, considering that the third-party check test should be carried out randomly as
directed by the Engineer on monthly basis.
WATERPROOFING OF PENETRATIONS
1. For steel dowel bars at approach slabs on corbels near tunnel roof level if applicable clean and coat the
bottom 10mm of the bars using Stirling Lloyd ZedS94 primer before applying Integritank membrane over
the corbel.
2. For pipe penetrations clean and coat of the pipes using Stirling Lloyd primer before applying Integritank
membrane around the pipe penetration. Refer to shop drawings for the type of primer.
3. Earthing and pipe penetrations shall be considered as special items of checking and waterproofing
arrangement around them shall be checked and signed by the subcontractor for each step which is
further to be inspected by the consultant. Necessary site adjustments shall be made on-site for the same
purpose other than approved drawings.
20.WATERPROOFING OF JOINTS
INSTALLATION OF WATERSTOPS IN EXPANSION JOINT
1. For Base Slab: Remove keys of PVC T-Lock Membrane approximately 200mm either side of expansion
joint centerline. Place external waterstop on the PVC T-lock membrane and hot weld edges of waterstop
(20 mm wide) continuously. Place internal waterstop in correct location. Tie back edges of waterstop to
reinforcement using plastic ties or tie wire to keep waterstop flat and straight.
2. For Walls: Place external waterstop against formwork and staple edges of waterstop to keep the
waterstop in place. Place internal waterstop in the correct location. Tie back edges of waterstop to
reinforcement using plastic ties or tie wire to keep waterstop flat and straight.
3. For Roofs: Place dilation tape centrally over expansion joint and adhere concrete using Metaset
structural adhesive as shown in drawings. Place internal waterstop in the correct location. Tie back edges
of waterstop to reinforcement using plastic ties or tie wire to keep waterstop flat and straight.
4. The tie-in at the project limit will be specially studied, detailed, adjusted, and done on-site with each
step confirming as per approved mock-up.
INSTALLATION OF PROTECTION TO WATERSTOPS
1. For Walls: Place PVC protection strip over external waterstop and adhere edges using Metaset
structural adhesive in accordance with the drawings.
2. For Roofs: Place PVC protection strip over dilation tape and adhere edges using Metaset Structural
Adhesive in accordance with drawings.
INSTALLATION OF INJECTION HOSES
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Property of MSS – Approved (Controlled document in Document Repository)
FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 826 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
1. For Construction Joints: Place injection hose directly onto the concrete substrate in location as shown in
the drawings. Drill and fix hose clamps at 250 mm center approximately to firmly hold the injection to the
concrete. Connect clear hose at the termination of injection hose with a hose connector and fit injection
point. Place injection point to reinforcement and formworks at locations as directed by the drawings.
2. For Expansions Joints: Place one injection hose on each edge of the internal waterstop. Fix hoses to
waterstop with plastic ties. Connect clear hose at the termination of injection hose with a hose connector
and fit the injection point. Place injection to reinforcement and formwork at locations as directed by the
drawings as directed on the drawings.
3. X1 hoses typically to be installed in walls for Construction Joints and Expansion Joints where distances
between injection points are below 20m. X100 hoses typically to be installed in base slab and roof for
construction joint and expansion joint where distances between injection-points for 40 m length.
4. Test Report for X100 injection hose is attached in Appendix P. The same shall be confirmed by a mock-
up test.
5. The location of injection hose points should be in one align with constant distance for base slab (500
mm above final floor finish), wall, and roof slab.
INSTALLATION OF SWELLING BAR
1. Place Superswell 47B in the center of the construction joint as shown on the drawings and fix to the
concrete substrate using contact adhesive to keep the swelling bar firmly in contact with the substrate.
BACKFILLING, PROTECTION AGAINST BACKFILLING AND REPAIRS
1. Protection board to be installed against vertical waterproofing membrane as required prior to
backfilling. Careful layer by layer monitoring of the backfilling operation will be carried out and approved
by the subcontractor to be aware of any damage caused to the membrane by the compaction equipment.
Any damage shall be repaired immediately.
2. The wall will have a protection board and backfilling to be witnessed and monitored by the
subcontractor and main contractor for damage to the waterproofing. If the damage is observed then the
backfilling operation is to be halted until repairs are completed and inspected.
3. For the roof slab, a protective concrete screed of 75 mm thickness shall be installed directly on the
Integritank if a protection screed is demanded.
4. During backfilling work the work will be witnessed and reinforced for any damage caused to the
waterproofing from the backfilling operation. Repairs to the damaged membrane will be immediately
undertaken in accordance with the method statement for the waterproofing system.
5. For performing backfilling, its layer thickness, operation sequence, and testing criteria, reference shall
be made to approve revision of method statement for respective backfilling activity.
6. Backfilling material around of structure shall only be hand placed.
Compaction of backfilling within 1.5 m of the structure shall only be achieved by manually operated tools
& equipment. Towed or self-propelled vibrating rollers or heavy compaction equipment shall not be used
within 1.5 m of any structure.
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 827 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
7. Backfilling shall be done with approved backfilling material. Up to 1.5 m from the structure, backfilling
shall be done with stone/rock particles having a size not more than 0 – 50 mm with a manually operated
compactor. For area more than 1.5m away from the structure, backfilling shall be carried out with
stone/rock particle not more than 75 mm.
8. For structural backfill, the material shall be placed in a layer within the effective range of compaction of
the plant provided that the maximum loose (uncompacted) thickness of each layer shall not exceed 200
mm to 300 mm. The compacted thickness shall be about 150 mm.
9. Each layer of fill shall be checked and assessed by a waterproofing subcontractor and a separate
checklist will be signed to ensure no damage on the waterproof sprayed membrane prior to proceeding
for the next layer.
21.RISK ASSESSMENT
Please refer to attached document on Appendix D.
22. PERMIT AND LICENSING REQUIREMENTS
All necessary permits shall be obtained.
23.DIAGRAMS, MAPS AND SURVEY DATA
Please refer to Typical Drawing ref. no.: xxxx.
24.PRE-START SAFETY BRIEFING ARRANGEMENTS
Refer to Risk Assessment on Appendix D.
1. Protective and Safety Equipment
All workers Involved shall be equipped with adequate PPE as stated below:
a. Safety Helmet with Company Logo
b. Safety Boots
c. High Visibility Vest
d. Safety Goggles
e. Hand Gloves
f. Coveralls
2. Information to Personnel
a. Safety Induction
b. Job training
c. Superintendents Notices/Memos
d. Toolbox talks
e. START Card
3. Special Safety Requirements
a. All necessary personal/protective equipment (PPE).
b. Banksman, wearing distinctive vests, shall be assigned to help operators maneuver their equipment.
c. The equipment operators shall possess the required licenses and certificates.
d. Generated dust shall be controlled by periodic water spraying.
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 828 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
e. The required TSTI will be prepared prior to commencement of work and positively implemented.
f. The project safety officer is responsible along with the project zone site engineer for ensuring that all
operations are carried out with due regard to the safety of all project personnel & property.
g. All working activity shall comply with Client Safety Procedure.
h. First aid material.
i. General management of protection/operation hazards are to be observed.
4. Emergency Procedures
The Flow chart below (insert below the responsible persons and their respective contact numbers) shows
the emergency contact number during work.
25.SUPERVISION AND MONITORING ARRANGEMENTS FOR WATERPROOFING WORK
CONSTRUCTION MANAGER
He is in charge of all construction activities. Schedule the project in logical steps and budget time
required to meet deadlines. Inspect and review projects to monitor compliance with building and safety
codes and other regulations.
TEMPORARY WORKS CONSTRUCTION MANAGER
To support the project delivery teams, to support and lead the management and delivery of temporary
works engineering whilst ensuring program, cost, quality, and safety objectives are achieved.
SITE ENGINEER
The Site Engineer shall evaluate the number of materials consumed by each trade to be compared
against the planned quantity.
SITE FOREMAN
A construction foreman is responsible for supervising the workers and also doing actual construction
work. The foreman monitors employees to ensure that the work is done efficiently and within quality
standards.
CHIEF SURVEYOR
A Chief Surveyor ensures that surveying data are collected and recorded accurately and that all company
procedures are followed by crew members.
QA/QC ENGINEER
The QA/QC Engineer shall monitor whether the installation works are conforming to the required quality
otherwise he shall notify the Site Engineer should he found non-conformance to the ongoing activities.
The Site Engineer shall immediately rectify the work to avoid receipt of NCR from the QA/QC Engineer.
HSE ENGINEER
The Safety Engineer shall be full time at the site and shall frequently visit all the ongoing works at the
site. All safety violations and on-conformance of the HSE Plan shall be registered and immediate action
shall be done in coordination with the Site Engineer.
ENVIRONMENTAL MANAGER
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 829 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
Will closely monitor implementation of MS and Risk Assessment, the proper storage and handling of
materials.
LIFTING COMPETENT PERSON
The role of the Lifting Competent Person is to ensure compliance to safe practice for the loading and
unloading of equipment and materials on site.
27 .ENVIRONMENT AND QUALITY ISSUES
1. Precautionary Measure
All precautionary measures shall be briefed to all workers prior to commence activity
2. Disposal Requirements
All waste shall be disposed as per the Construction and Environmental Management Plan, ref.: xxxxx, and
as per Government approved disposal areas.
3. Inspection, Test and Sampling
Request for Inspection and Testing will be submitted prior to and after the execution of works.
A mock-up sample shall be provided on-site for approval prior to the execution of works where required.
4. Quality Assurance Requirements Table Refer to Project Quality Plan
a. Project Specifications
28.ATTACHMENTS
REFERENCE DOCUMENTATION
a. Technical Data Sheet
LIST OF APPENDICES
Appendix A: Site Location
Appendix B: Shop Drawing, ref.: xxxxx
Appendix C: Field Testing and Inspection Plan
Appendix D: Risk Assessment and Job Hazard Analysis
Appendix E: Pictures of Instruments
Appendix F: Formats for Inspection and Checking
Appendix G: Photographs for Installation of Integritank
Appendix H: Copies of References
Appendix I: Method of T Lock Field Testing
Appendix J: Application Guidelines – Integritank
Appendix K: Calibration Certificates
Appendix L: Subcontractor Organization Chart and Contact Numbers
Appendix M: Confirmation from Stirling Lloyd on Moisture and DT
Appendix N: Test Report for X100 Injection Hose (42.0 meter)
29.METHOD STATEMENT FOR WATERPROOFING OF ROOF USING EPDM MEMBRANES
PRODUCT DELIVERY, STORAGE, AND HANDLING
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 830 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
A. Deliver materials etc.: the job site in the manufacturer’s original, unopened containers or wrappings
with the manufacturer’s label, brand name, and installation instructions intact and legible. Comply with
the manufacturer’s written instructions for proper material storage.
1. Store materials except for membrane, between 15°C and 27° in air-conditioned space (container)
protected from water and direct sunlight.
2. Store materials containing solvents in dry, well-ventilated spaces with proper fire and safety
precautions. Keep lids on tight.
B. Material inspection shall be carried out for all permanent materials. Any materials, which are found to
be damaged, shall be removed and replaced.
GENERAL WORK CONDITION
a. Work Sequence
1. Schedule and execute work in accordance with site construction program and with site conditions.
2. Do not disrupt activities in occupied spaces.
TEMPORARY FACILITIES AND CONTROLS
A. Temporary Utilities:
1. Water power for construction purposes and lighting should be available at the site and should be made
available when required.
2. When available, electrical power should be extended as required from the source.
Provide all trailers connections and fused disconnects.
B. Temporary Sanitary Facilities
Sanitary facilities should be available at the job site.
30.MATERIALS
Hot applied liquid membrane: Shall be CCW SOC H0i Applied Membrane, rubberized asphalt compound
Reinforcing fabric: Shall be reinforcing fabric which is a 1.35 oz/square yard spun bonded polyester fabric
Primer
EPDM 1.52mm thick waterproofing membrane
Bonding adhesive
Tape 15.24 cm wide
Splicing Cement
Extruded Polystyrene Insulation Board (50mm Thick) (32-36 kg/m³)
Termination bar
Lap Sealant
Water Cut-off mastic
Geotextile separation and protection layer
Paver Mixed (Aggregate)
Gravel 20-40mm
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 831 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
31.PROCEDURE FOR WATERPROOFING OF ROOF USING EPDM MEMBRANES
SURFACE PREPARATION
The surface should be free from defects. Any surface defects to be repaired as per approved MS –
Repair of Concrete, prior to screed works.
Sand-Cement screed (thickness min. 50mm to 150mm max.) laid to fall will be casted on top of roof
slabs as per approved drawings.
Install a 50 mm x 50 mm angle fillet on all internal corners.
APPLICATION OF HOT RUBBERIZED MEMBRANE
Works shall be carried out according to the manufacturer’s application and installation instruction.
TO HORIZONTAL GRADE:
A. Heat the membrane blocks in a twin wall kitten with continuous agitation and apply at temperatures
between 190.5°C to 201.6°C (Caution: Do not exceed maximum safe operating temperature of 204.4 °C.
B. Apply heated hot applied membrane at a rate of 1.62 sq. m. per gallon or as required to obtain an
average thickness of 2.2 mm over the primed area.
C. Apply the reinforcing fabric and any required flashings while membrane is still warm and tacky. Cut
and trim off any wrinkles or overlap sections of the reinforcing fabric.
D. Apply a second coat of hot applied membrane as required to obtain the total thickness of 4.5 mm.
E. Flash all penetration to conform with manufacturer’s recommendations and as shown on approved
drawings.
TO VERTICAL GRADE:
A. MEMBRANE INSTALLATION
Follow manufacturer’s applicable specifications for particular surface preparation procedures, membrane
positioning and adhesive application requirements.
In preparation for membrane splicing, overlap adjoining EPDM membrane sheets approximately 15.2 cm.
B. MEMBRANE SPLICING WITH TAPE
Tape splices must be a minimum of 13.9 cm wide using 15.2 cm wide tape extending 0.3 cm minimum to 1
.2 cm maximum beyond the splice edge.
Prior to tape and flashing application, the splice area must be primed.
C. MEMBRANE TERMINATION
Upper ends of the EPDM membrane should be held tight using termination bar, water cut-off mastic and
sealed with approved sealant.
D. Flash all penetration to conform with the manufacturer’s recommendation and as shown in the
approved shop drawing.
On completion of application of waterproofing material to an existing concrete roof but before the
application of insulation and protection, seal off all rainwater outlets and flood the roof to a depth of
25mm. The Contractor shall make up any loss of water due to evaporation or leaks. After 48 hours, visual
inspection of the roof shall be undertaken from inside the building in the presence of the
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 832 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
Consultant to establish if there are any leaks in the structure. The Contractor shall locate and seal any
leaks.
Carry out inspections in accordance with the ITP (Inspection and Test Plan).
Fit aluminium flashing with sealant to terminations of the membrane on walls.
Install polystyrene boards in a neat tight fit.
Install geotextile layer.
Install gravel layer and concrete pavers in accordance with drawing layout.
32.METHOD STATEMENT FOR WATERPROOFING USING CEMENTITIOUS MEMBRANES – WET AREAS SUCH
AS BATHROOMS, LIFT PITS, TERRACES, PANTRY, ETC.
MATERIAL:
Acrylic cementitious waterproofing membranes
PROCEDURE:
For Concrete Base Surface Preparation:
Structural cast in-situ reinforced concrete slab dry, smoothly finished and, clean from construction
debris.
Concrete upstand shall be dry, clean and smoothly finished.
CMU (Concrete Masonry Units) upstands must be properly plastered and, smoothly finished.
Establish a 50 x 50 mm mortar canstrip at junction lines between horizontal and, vertical surfaces.
Upstand edge lines should be slightly chamfered and smoothly finished.
Setup mortar cones around the base perimeter of service pipes protruding from the concrete slab.
Prepare the concrete threshold at wet areas door entrance minimum 80 mm height, and according to
actual site conditions. This will serve as a barrier during water testing after the waterproofing
application.
33.MEMBRANE APPLICATION:
The surface to be coated with acrylic cementitious waterproofing membranes must be slightly damp to
ensure a firm enduring bond to the substrate.
Temperature condition:
Acrylic cementitious waterproofing membranes shall be used when the ambient temperature is above
5°C.
In hot water, areas to be coated shall be shaded from direct sunlight.
Mixing:
The acrylic cementitious waterproofing membranes shall be mixed in a clean container.
The powder shall be added slowly to the liquid component. Utilizing a slow speed drill with a suitable
mixing head, mix for a minimum of 2 minutes, until a homogenous lump-free consistency is obtained.
Application:
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 833 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
Two coats of acrylic cementitious waterproof coating, at the rate as per manufacturer’s recommendation
complete with mesh reinforcement strip at junction lines between horizontal and vertical surfaces and
around pipe penetrations.
Curing:
As per manufacturer’s material specification
34.TEST:
Water test should be conducted for the completed areas for a period of a minimum of 24 hours prior to
the application of the tiling and finishing items.
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 834 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
METHOD STATEMENT FOR
ANTI CARBONATION COATING
SR. EFFECTIVE REV. MSS MANAGER MSS PROJECT CLIENT
CLIENT QA/QC
NO. DATE NO. QA/QC MANAGER SUPERVISOR
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
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METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 835 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
ANTI CARBONATION COATING
1. PURPOSE
The method statement for anti-carbonation coating defines the control procedures, technical details
covering surface preparation, pre-application, during application and completion of application method,
to achieve the optimum performance for the specified anti-carbonation treatment used in concrete
substrates.
Anti-carbonation coating is surface treatment primarily used to protect the concrete substrates from the
ingress of contaminants such as carbon dioxide (in reinforced-concrete construction, the chemical
reaction between carbon dioxide in the air and calcium hydroxide and hydrated calcium silicate in the
concrete is known as neutralization), chlorides, acid gases, water sulfates, and sulfur dioxide.This
protection extend the design life of a reinforced concrete structure. Such a barrier prevents further
corrosion of steel reinforcement and subsequent spalling of the surrounding concrete.
1. INTRODUCTION
This Method Statement defines and describes the control procedures, technical details covering surface
preparation, pre-application, during the application, and completion of the application, to achieve the
optimum performance for the specified Anti-Carbonation Coating using xxxxx (or equivalent approved
material) for (Name of Project).
2. DEFINITIONS
xxxx Company / Client
xxxx Project Management
xxxx Supervising Consultant
SE Site Engineer
QC Quality Control Engineer
SF Site Foreman
PM Project Manager
SA Site Agent representative from the Lab
HSE Manager Health, Safety & Environmental Manager
HSE Officer Health, Safety & Environmental Officer
xxxx Main Contractor
GIS Geographical Information System
PS Project Specifications
CEMP Construction Environmental Management Plan
QCP Quality Control Plan
HSE Plan Health, Safety and Environment Plan
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
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METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 836 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
GWL Ground Water Level (meter)
NGL Natural Ground Level (meter)
Note: All dimensions are in mm unless specified.
3. REFERENCE
Technical Data Sheets
HSE Plan
CEMP
Material Approval Submission for Anti Carbonation System
4. RESPONSIBILITIES
PROJECT MANAGER
Responsible for accomplishing the stated project objectives which include creating clear and attainable
project objectives, building the project requirements, and managing the constraints of the project
management triangle, which are cost, time, scope, and quality.
The Project Manager shall be responsible for ensuring that the Project Quality Plan and the Inspection
and Testing procedures, method statement, HSE safety, and all contractual documentation are
maintained up to date and accessible to all parties.
CONSTRUCTION MANAGER
Responsible for overall construction activities ensuring that the method statement for anti-carbonation
coating, quality, and safety procedures are implemented and required approval permits are obtained.
SITE ENGINEER
Supervise operations in accordance with the approved Method Statement, shop drawings,
specifications, material submittals and schedules to achieve the acceptance of the project deliverables.
QA/QC ENGINEER
QA/QC Engineer is responsible to ensure work has been done as per the approved method statement;
inspections are done as per Quality Control Procedure and as per QA/QC Checklist.
CHIEF SURVEYOR /LAND SURVEYOR
Carry out a pre-construction survey to fix the locations and corresponding elevations as per the
approved shop drawings.
Ensure the quality and compliance during phases of surveying works and the regular checking of the
surveying equipment or periodic calibration from a third party.
Ensure the validity and the serial number of calibration certificates are available and posted in the
survey equipment.
Ensure proper safety guarding of surveying equipment.
To maintain the records of all surveying equipment handled.
SCAFFOLDING MANAGER /SUPERVISOR
Ensuring safe access is provided for scaffolders to work.
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FORMATE ID:
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NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
Ensuring that all his Foremen, Team Leaders, and workers are conforming to site safety regulations and
are Third Party Certified (TPC).
Ensuring that all scaffolds are erected according to site scaffold procedures.
Ensuring that scaffold schedules are met and still working within the site safety regulations.
Ensuring that material and workers are available to meet the site scaffolding requirements.
Ensuring that all documentation adheres to Tool Box Talks, Harness Inspection, Site Request System,
Scaffolding Tagging System, and Safety reports.
SURVEY AIDE
Maintain and use Surveying equipment. Assist Surveyors in taking measurements, record
measurements manually or electronically, and peg out boundaries.
HSE MANAGER
Health, safety, and environmental (HSE) managers generally plan, coordinate, and implement issues
and directives within the organization.
They ensure safe environmental working conditions for all employees.
HSE ENGINEER
Ensure enforcement of safety procedures in accordance with the approved HSE Plan.
Will be closely monitoring the site engineer’s strict implementation of the MS and Risk Assessment, the
use of proper tools and equipment to maintain safety, certifications of equipment and their adherence
to safety regulations, reporting of any unsafe work, or stopping work that does not comply with ES&H
procedures.
FIRST AIDER
The first aider respond promptly when requested, operate with competence, know how to secure
additional help when needed, reports incidents and actions taken and comply with requirements for
certification.
5. INTERFACING WITH OTHER OPERATIONS
Concrete Works
6. DURATION, PHASING WITH THE SUBCONTRACTORS
The work is indeterminate but shall not critically affect the progress of works.
7. LIST OF SUBCONTRACTORS
Subcontractor/Supplier:
xxxxx
8. RESOURCES
PLANT, EQUIPMENT AND TOOLS
Description No. of Units Application
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Page 838 of 864
NAME OF CLIENT: KAMOA COPPER S.A.
MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
Wire brush, sand paper,
1 Surface Preparation
Carborandum stone etc.
Water Jetting Equipment / Grinder 4 Surface Preparation
Roller, Scraper, Spray Equipment,
1 Application of Paint
Compressor
WFT Gauge – preferably Aluminum 1 Film Thickness Reading
Moisture Meter 1 Moisture Reading
PosiTector 200 DFT Meter 1 Coating DFT Measuring
Dew Point Meter 1 Dew Point Reading
WORK FORCE
Designation No. of Persons
Site Engineer 1
QA/QC 1
Land Surveyor 1
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TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
Page 839 of 864
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MINING SERVICES & SUPPLIES S.A.S. RETURN TO INDEX
CONTRACTOR
NAME:
Survey Aide 1
HSE Engineer 1
First Aider 1
Scaffolding Team 1 team
Helper 2
Painter 1 team
LIGHT TOOLS
Description No. of Units Application
Hand Tools As per Site Requirement For Construction
Power Tools As per Site Requirement For Construction
9. MATERIALS
Approved Anti Carbonation Coating/Paint
Repcoat Primer (example/replaced it with the equivalent approved material)
Repcoat (example/replaced it with the equivalent approved material)
10. SITE PLANNING
Duration of work shall be indeterminate but will not critically affect progress of the project.
PREPARATION
Permits from the concerned authority shall be obtained prior to start work at the site.
The contractor shall ensure that all gate passes, permits, tools, materials for safety precautions,
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FORMATE ID:
MINING SERVICES & SUPPLIES MSS/MS/PRJ-001
REV NO.: 00
S.A.S. EFFECTIVE DATE:
DOCUMENT
METHOD STATEMENTS
TITLE:
PROJECT NAME: CIVIL AND EARTHWORKS CONSTRUCTIONPLANT AND PASTE PIPELINE
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manpower, and equipment are available before the commencement of work.
The Site Team shall make sure that access roads are always clear from any obstruction and site is always
accessible.
Provision of access and egress such as ladders, steps, ramps, or other safe means of egress and be with
reasonable distance and must be extended at least 1.0 m above the ground.
SITE CLEARANCE
Before commencement of activity, the work area shall be cleared of all debris, materials or other
obstructions.
TRAFFIC MANAGEMENT
The Site Team with the assistance of the Safety Officers shall coordinate logistics and materials
movement through site following the direction and road signs displayed on site. The required
diversion routes shall be marked on drawings including the required traffic signs.
The Work Permits and Operator Certificates shall be compiled and files for reference by authorized
personnel.
PRE-CONSTRUCTION SAFETY MEETINGS
The meeting shall be scheduled prior to the beginning of the work and before any Sub-contractor
starts on the project.
General contractual safety, health, and environmental requirements.
Traffic safety will be discussed to emphasize these meetings.
Roles of the contractor, subcontractors, authorized representatives, and all project workers.
Accident reporting requirements.
Specific details of the work to be performed along with the use of personal protective equipment.
11. PROCEDURE – METHOD STATEMENT FOR ANTI-CARBONATION COATING
Repcoat is a one-component water-based acrylic elastomeric protective and carbonation coating system.
This product has excellent concrete protection properties that protect concrete against concrete
carbonation, moisture, chloride attack, UV degradation, minor cracks, etc. and is ideal for concrete
bridges.
SCOPE OF WORK
The scope of work includes the detailed requirement for the preparation and application of all products
to be used in the specified coating system.
PROPOSED SYSTEM:
Repcoat Primer (full coat) (example/replaced it with the equivalent approved material)
Probuild PF200 (touch up) (example/replaced it with the equivalent approved material)
Repcoat (full coat) (example/replaced it with the equivalent approved material)
Repcoat (full coat) (example/replaced it with the equivalent approved material)
SUBSTRATE / GENERAL REQUIREMENTS
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All painting shall be strictly carried out in accordance with the project specifications and manufacturer’s
recommendations.
The contents of the safety data sheets are to be briefed to the operating staff and ensured that they
understand the risks and are clear on the required/necessary control and PPE measures.
A program and sequencing have to be done by the construction team for the painting of the different
areas to ensure that structures can be coated in a continuous operation with paint from the same batch.
The surface to be coated shall be in ready condition. All necessary repairs to exposed concrete surfaces
are to be completed well in advance of the painting to ensure repairs/curing agents have completely
dried out.
The substrate shall be fully cured before starting any painting works.
The substrate should have enough strength to carry out painting works. A scratch with a metallic nail
should not produce a deep impression.
The substrate should be free from oil, grease and other chemical impurities.
No application of the coating in the works shall be undertaken until trials have been complete and site
samples are approved.
Areas/items that need protection adjacent to the painting area shall be masked off.
No coating will be performed during sandstorm/ windy, rainy, and similar climatic conditions. If it begins
to rain while coating application, the coating job has to be stopped and the affected area has to be
repainted later.
Moisture content in the substrate has to be less than 4% when tested with a moisture meter.
The substrate should be sound, clean, and free from dust & flaking materials. All holes and deep cracks
should be filled with suitable fillers. Remove any traces of oil, grease, chemical contaminant, mold &
algae, treated with suitable anti-fungicide or bleach solution.
12. QA / QC
Ensure a dry, clean and sound substrate.
Measure moisture content in the substrate and ensure that it does not exceed 4% (when tested with a
calibrated moisture meter).
Use WFT gauge at regular intervals to control the wet film thickness during all stages of the application
procedure. Dry film thicknesses can be converted from the wet readings using the following formula;
(WFT X V.S %) / 100 = DFT.
DFT will be tested using the PosiTector 200 to ensure the DFT 300 micron for the full system.
Ensure sufficient ventilation during and immediately after painting.
Avoid painting if the substrate temperature is above 55 °C.
Avoid painting if the relative humidity % where the painting is taking place is above 85%.
On exterior areas, avoid painting during windy and rainy conditions.
13. SURFACE PRE-TREATMENT
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Any traces of oil and grease are to be thoroughly removed with a suitable emulsifier to be applied by
using a stiff brush and once removed, the area shall be freshwater rinsed ensuring all traces of residues
are removed.
SURFACE PREPARATION
All surfaces should be mutually inspected before starting the painting works to ensure that all surfaces
are ready and suitable to apply the protective coating.
The substrate will be kept dry, clean and free from any laitance, wax, grease, dirt and oil or any
materials could affect the bond.
All cracks and unsound concrete will be repaired before starting the application by using approved
repair materials.
All blowholes & minor imperfection will be repaired.
On new cementitious substrates leave for 14 days before coating. If in doubt leave for up to 30 days to
fully cure before coating.
All surfaces should be applied by high water jetting to make ready for the primer coating.
14. SYSTEM APPLICATION
PRIMER COAT
Substrate temperature, moisture content, and relative humidity should be tested and recorded before
the starting of the primer application if the concrete substrate age is less than 14 days.
Repcoat Primer Siloxane Acrylic Primer is ready to use a material that requires thorough stirring with a
mixing stick prior to application. Repcoat Primer is a ready for use, single component primer based on a
silane/siloxane and an acrylic resin providing protection from rebar corrosion, efflorescence, freeze-
thaw damage, water penetration, oil penetration, mold, and mildew.
Apply evenly by use with brush or textured roller at a rate of Horizontal application: 0.2 – 0.4 litre/m² (or
2.5-5 m²/liter) & Vertical application: 0.1 – 0.2 liter/m².
We should wait for a minimum of 12 hours after priming and before the application of Repcoat.
The primed substrate should be sound, dry, clean, and free from dust or other contamination.
TOP COAT
For each independent area of application sufficient materials, equipment and labors will be arranged.
We can apply Repcoat with in temperature (5°C – 38°C).
A first coat will be applied by airless spray machine with a coverage of 0.3 liters/m² to achieve 150-
micron dry film thickness.
We should wait at least 2 to 4 hours at 35°C and 4 to 6 hours at 25°C from the application of the first
coat at the same rate.
A second coat will be applied at a right angle to the first coat by airless spray machine with a coverage
0.3 liter/m² to achieve 150-micron dry film thickness.
If the overcoating time (8 hours) is exceeded, the first coat will be abraded with sandpaper prior to the
application of the second layer.
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Total dry film thickness will be kept 300 microns.
Two coats should always be used on dark, full heavy textured surfaces and when full carbonation
protection required.
15. STORAGE OF COATING MATERIALS
All material delivered to the site must be stored in accordance with local regulations and manufactures
recommendations. It is recommended to store all paint material in shaded, dry, cool, and well-ventilated
stores that are away from sources of heat, ignition, and sunlight. Containers must be kept tightly closed.
Storage area conditions at temperatures between 10°C to 35°C. The shelf life of 12 months from date of
manufacture in proper store condition. For further information, please consult the separate material
safety data sheets.
GENERAL NOTES
Care should be taken to remove masking tape immediately after each coat, without allowing the paint to
dry.
All corners/edges should be rounded off properly with the roller before allowing each Repcoat coats to
dry.
Before the application of each coat, ensure that all dust and other surface contaminants on the previous
coat are removed.
Please refer to the provided technical data sheet for each product to be used, following the
recommendations within.
16. RISK ASSESSMENT
Please refer to attached document on Appendix A.
17. PERMIT AND LICENSING REQUIREMENTS
Refer to Appendix B for Permit to Work.
Drawings, Diagrams, Maps and Survey Data
Please refer to Method Statement content.
Pre-Start Safety Briefing Arrangements
Refer to Risk Assessment on Appendix A.
18. PROTECTIVE AND SAFETY EQUIPMENT
All workers involved shall be equipped with adequate PPE as stated below:
a. Safety Helmet with Company Logo
b. Safety Boots
c. High Visibility Vest
d. Safety Goggles
e. Hand Gloves
f. Coveralls
g. Safety Harness
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19. INFORMATION TO PERSONNEL
a. Safety Induction
b. Job training
c. Notices/Memos
d. Toolbox talks
e. START Card
20. SPECIAL SAFETY REQUIREMENTS
a. All necessary personal/protective equipment (PPE) as well as harness be provided.
b. Banksman, wearing distinctive vests, shall be assigned to help operators maneuver their equipment.
c. The equipment operators shall possess the required licenses and certificates.
d. Generated dust shall be controlled by water spraying.
e. The project safety officer is responsible along with the project zone site engineer for ensuring that all
operations are carried out with due regard to the safety of all project personnel & property.
f. All working activity shall comply with Client Safety Procedure.
g. First Aid Material.
h. General management of protection/operation hazards are to be observed.
i. In the case of working at night, please refer to Method Statement for Night Works (Reference no.:xxxx)
21. ENVIRONMENT AND QUALITY ISSUES
PRECAUTIONARY MEASURE
All precautionary measures shall be briefed to all workers prior to commence activity.
DISPOSAL REQUIREMENTS
All waste shall be disposed of as per the Construction Environmental Management Plan and as per
Government approved disposal areas.
INSPECTION, TEST AND SAMPLING
Request for Inspection and Testing will be submitted prior to and after the execution of works.
22. QUALITY ASSURANCE REQUIREMENTS TABLE
Refer to Project Quality Plan
a. Project Specifications
23. ATTACHMENTS
1. Reference Documentation
Project Specifications
2. Appendices
Appendix A: Risk Assessment for Anti-carbonation Coating Application
Appendix B: Permit to Work
Appendix C: Inspection and Test Plan
Appendix D: Material Technical Data Sheet
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METHOD STATEMENT FOR
FALSE CEILING WORKS (WOODEN)
SR. EFFECTIVE REV. MSS MANAGER MSS PROJECT CLIENT
CLIENT QA/QC
NO. DATE NO. QA/QC MANAGER SUPERVISOR
FALSE CEILING WORKS
1. PURPOSE
A false ceiling or alternatively called drop ceiling is a fixed framework made of either aluminum, metal or
wooden batten covered with either material like Plaster of Paris, gypsum board, plywood, PVC sheets,
wood, metal ceiling tiles, glass, mineral fiber, etc. hung below the main ceiling.
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2. SCOPE & OBJECTIVES
This method statement describes the method of installation of suspended gypsum board and tile
ceiling with the use of metal framings in the project.
3. REFERENCES
Contract documents
Project Specification:
Contract Drawings:
Contractors Submittal
Project Quality Plan:
Project Safety Plan:
Material approvals (MAT)
Shop Drawings approvals (SPD)
Related method statements (MET)
4. DEFINITIONS / ABBREVIATIONS
DEFINITION
1. Project –(Replace with project name)
2. Client –(Replace with clients name)
3. Developer –(Replace with developers name)
4. Consultant –(Replace with consultants name)
5. PMC –(Replace with PMC name)
6. Contractor –(Replace with contractors name)
7. Sub-contractor -(Replace with sub-contractors name)
8. Supplier –(Replace with suppliers name)
ABBREVIATIONS
1. Engineer – Representative of “Name of engineering consultancy”
2. ICL – Inspection Check List
3. IR – Inspection Request
4. ITL -Independent Testing Laboratory
5. ITP – Inspection and Test Plan
6. ITR -Inspection & Test Requests
7. MAT – Material Submittal
8. MEP – Mechanical Electrical Plumbing
9. MET – Method Statement
10. MIR – Material Inspection Request
11. MSDS – Material Safety Data Sheet
12. PPE -Personal Protective Equipment
13. PQP -Project Quality Plan
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14. PTW -Permit To Work ( Working at Height or enclosed spaces)
15. RA -Hazard Identification and Risk Assessment
16. RFIA – Request for Inspection and Approval
17. SPD – Shop Drawing
18. TBM – Temporary Bench Mark
5. RESPONSIBILITIES/SUPERVISION
1. The project manager of the subcontractor is overall responsible for the implementation of the MS. He
will ensure that the supervisory staff allocated for this MS and all resources are in place for the
2. The site engineer is responsible to execute the installation work as per the approved MS. QA/QC
engineer of the subcontractor is responsible to ensure that work has been done as per specification and
inspections are done as per the approved ITP. Safety officer of the subcontractor is responsible to ensure
that all personnel on site are to abide by the project safety requirements.
6. EQUIPMENTS & TOOLS / MANPOWER / MATERIALS
PLANT & EQUIPMENT REQUIREMENT
Following tools will be used for installation of suspended false ceiling works.
1. Drills with bits for concrete and metal
2. Screw gun – Power tool that drives all types of gypsum board screws through gypsum board and into
framing or substrate
3. Powder-actuated tool ( E.g. Hilti Gun fastener)
4. Chalk line
5. Sprit level
6. Metal cutting scissors
7. Measuring tape – A steel retractable measuring tape, usually 25 feet in length.
8. Gypsum board T-square –Square edge for measuring and cutting gypsum board to length and for
cutting out holes for square outlet boxes and other openings.
9. Utility knife – the Standard cutting tool with replaceable/reversible blades for scoring and cutting
gypsum board.
10. Hammer – Drives nails through gypsum board into wood framing.
11. Keyhole saw – Small triangular saw for cutting out holes for outlet boxes, pipes, and other
penetrations.
12. Assorted trowels and taping knives – Bladed tools for applying and smoothing tape and joint
compound over joints and fastener heads.
13. Tray / Box to contain joint compound while finishing joints and fastener heads.
MANPOWER REQUIREMENT
1. False ceiling technician
2. Labour
3. Supervisor/ Foreman
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4. Site Engineer
MATERIAL REQUIREMENTS
Following materials will be used for installation of suspended false ceiling works.
1. 12.5mm thick regular gypsum boards
2. 600x600x6mm thick calcium silicate tiles
3. 0.55mm thick suspension of framing elements
4. T-24 exposed GI suspension
5. 0.5 mm thick 600mm x 600mm Aluminum tile
6. Main Runners and Furring Channels of 0.55mm thick
7. PROCEDURE / METHOD TO BE EMPLOYED
SITE SURVEY
The receipt of the shop drawings approved the consultants the site will be surveyed and any discrepancy
found will be notified to the main contractor for clarification.
SETTING OUT
Setting out and marking will be done as per approved shop drawing ceiling height of various areas shall be
marked based on the benchmark provided by main contractor level will be transferred on all the corners
and chalk lines will be marked.
FIXING OF WALL ANGLES
The wall angles will be fixed along the marked ceiling line depending on the substrate at 600mm to center
spacing. Before fixing the wall angle the substrate has to receive necessary finishes as per the finish
schedule.
FIXING OF HANGERS
Fixing of hangers will be done as per the approved shop drawing layout details and using hanger
anchorage devices of the soffit as per approved material submittal. The position of the hangers will be
marked on the soffit of the slab, which has to be reviewed by main contractor site engineer upon receipt of
MEP clearance hangers shall be fixed at a spacing of 1200mm centres on both the directions where MEP
services are clashing with fixing hangers, additional supplies shall be provided by agreeing with main
contractor on site.
FRAME WORK
The framework will be done according to the approved shop drawings and with approved materials.
Framing members such as Main Runners and Furring Channels of 0.55mm thick shall be placed as a spacing
of 1200mm and entries respectively. Heavy recessed fixtures should be independent of the ceiling framing
stems.
FRAMEWORK INSPECTION AND MEP CLEARANCE
Upon completion of framework, respective areas shall be offered for main contractor and consultant
inspection. Inspection request will be raised on prescribed formats for first and second fix of ceiling.
Written clearance for MEP and associated works to be different stages for the uninterrupted flow of our
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works. Upon receiving the approval and MEP clearance. Void closures shall be started by gypsum board
installation. Gypsum boards of specified type (Regular) shall be applied to the framing using gypsum
screws at 200mm. For tile ceiling, the void closure will be done by placing calcium silicate tiles on the
complete grid work.
TAPING AND JOINTING FOR GYPSUM BOARD CEILINGS
The following coat will be applied over the joints.
1. First Coat / Jointing Coat
2. Second Coat
3. Third Coat
First coat is initial jointing process where the fiber tape is fixed over the thin joining compound applied
over the joints. Another layer of jointing compound application would be done over the tape. This would
be approximately 75mm wide. Screw heads also will be covered by the application of the joint compound.
The second and third coat will be applied successively after having dried the previous coats. Each
successive coat to be feathered 40mm beyond the previous layer sides of the joint. This would be sanded
smooth after drying and leave for receiving decoration by following trades.
FINAL CHECK-UP
On completion of taping, jointing and sanding subcontractor supervisor will check the level and make sure
that is in true level and the work is within the tolerance limits.
CLEANING AND HANDOVER TO THE MAIN CONTRACTOR
When all our activities are completed, the area will be clean thoroughly. Once the cleaning is done and
approved subcontractor’s site in-charge a “Request for inspection” could be raised by him to main
contractor for their acceptance to issue the substantial completion of works certificate. The area then
would be handed to the main contractor or the succeeding contractor for further finishes/decoration.
8. HEALTH AND SAFETY HAZARDS:
Specific safety measures have to be followed as applicable, and all the safety measures are covered
separately in the Project Safety Plan.
9. ATTACHMENTS
Inspection Checklists
Inspection Test Plan
Risk Assessment
Technical Data Sheet (TDS)
Material Safety Data Sheet (MSDS)
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METHOD STATEMENT FOR
WATERSTOP INSTALLATION
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SR. EFFECTIVE REV. MSS MANAGER MSS PROJECT CLIENT
CLIENT QA/QC
NO. DATE NO. QA/QC MANAGER SUPERVISOR
INSTALLATION OF WATERSTOP
1. INSTALLATION OF WATERSTOP
Installing the waterstop in such a way that it produces a continuous waterproof diaphragm is a must.
The installation of a waterstop system is important to its efficiency and effectiveness; most failures occur
because adequate steps are not performed.
Dumbbell and ribbed center-bulb waterstops should be positioned so that the waterstop’s longitudinal
centerline aligns with the joint’s center. To provide the installer with a convenient means of fastening
the waterstop to neighboring steel rebars, hog rings or grommets are added to the furthest edges of the
waterstop profile (typically at 305-mm [12-in.] intervals) prior to the initial concrete pour. To attach the
waterstop and maintain proper alignment, tie wire is passed through the hog rings.
Several manufacturers recommend positioning the waterstop such that it covers at least half of the
concrete’s width. To avoid poor concrete consolidation caused by aggregate bridging, a minimum of two
times the greatest aggregate size should be allowed between the waterstop and reinforcing steel.
In addition, for varied head pressures, one must follow the manufacturer’s requirements for concrete
embedment depth.
As a general rule, the waterstop is installed with more concrete coverage for higher hydrostatic pressures.
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Splicing is required at intersections, changes of direction, or to produce larger lengths of waterstops. Ends
should be squared off before welding neighboring rolls together to make a continuous diaphragm. Welds
should only be performed by qualified individuals using approved equipment and techniques.
For the convenience of handling and manufacturing, uncoil water stop coils and lay flat for 24 hours
before installation.
To avoid sticking the waterstop material, heat is provided using a thermostatically controlled electric
splicing iron with a Teflon-film cover. The waterstop ends are pressed against the hot iron until the
material becomes somewhat molten after the iron has been preheated to the temperature indicated for
the type of thermoplastic material.
The splicing iron is removed, and the molten ends are pushed together and kept in this position until cold
(less than one minute). Waterstops constructed of thermoplastic materials should only be used with this
heat-splicing procedure. Waterstops made of traditional rubber are often cold-spliced using specific
adhesives.
Split-forming is utilized to keep the waterstop in place at vertical joints. Special split-leg profiles, on the
other hand, can be nailed to regular concrete forms. The center of the profile must be aligned with the
center of the joint in all installations.
The majority of waterstop failures are caused by weak welds or a lack of welding, according to
investigations. Splices should be checked to ensure that they are welded through the entire profile
thickness, not just on one side’s surface (i.e. edge welding).
Look for scorched, burned, or otherwise tainted welds as well. Furthermore, the central bulbs and ribs
must be kept in the same place throughout the weld. Any product’s integrity is substantially jeopardized
by edge welding waterstop.
Because the thin-edge weld lacks sufficient tensile strength and elongation compared to the parent
material, even minor movement of concrete can rupture edge welded splices.
Field-welded mitered fittings have proven challenging to splice accurately in the past. As a result,
directional change fittings (such as Ls, Ts, and crosses) should be prefabricated by the manufacturer,
leaving only simple butt-splicing to be done in the field.
A conventional flat cross fitting, for example, includes 12 cuts and seven welds. All cuts and three welds
are omitted from fieldwork when prefabricated fittings are used.
The directional change fittings are the most leak-prone location. Because the waterstop manufacturer has
specialized equipment and templates unavailable to the contractor in the field, prefabricated fittings can
eliminate or considerably decrease this problem. Both vertical and flat Ls, Ts, and crosses are offered.
During installation, debris, oil, or release agents must not be allowed to contaminate the waterstop
surface. Surface contamination might obstruct concrete’s direct contact with the waterstop, reducing its
effectiveness.
Concrete must be put with care so that the waterstop remains in place. During the first half of the
concrete placement, the waterstop must be properly held in place, with one-half of the width immersed
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in the concrete. To guarantee the waterstop remains in place during both phases of the concrete
installation and consolidation, this must be closely checked for quality control.
The PVC waterstop is frequently displaced, folded over, or misaligned with the joint, preventing it from
functioning properly.
Additionally, any concrete that has extruded out into the flange must be removed in horizontal-run
installations. Finally, employees installing the reinforcing bars frequently burn, puncture, or cut
the waterstop, so it must be inspected for any damage.Construction, contraction, and expansion joints
can all benefit from base-seal profiles. Interior wall transitions should not be made using base-seal since
the embedment ribs are only on one side and hence cannot operate properly.
Waterstops for the base is installed before the concrete is poured, and they can be set on compacted
grade, mud slabs, or vertical formwork. Only the ribbed side of the waterstop engages the concrete when
used as a base-seal waterstop.
Because the base-seal waterstop is not embedded in the concrete, it requires a firm substrate for initial
support and proper in-service performance. When exposed to significant hydrostatic pressure, a lack of
support might cause the waterstop’s edge to curl.To avoid movement or displacement of the waterstop,
care should be used when placing concrete. Base-seal types with a center-bulb tear-web can support the
joint movement. Manufacturers recommend ribbed center-bulb inserted in concrete instead of base-seal
products for high hydrostatic head pressures.Finally, in tight areas, one must always wear protective
equipment such as temperature-resistant gloves, safety eyewear, protective shoes, and a respirator.
Welding should be done in an environment that is well ventilated.
2. KEY TAKEAWAY-INSTALLING WATERSTOPS
Installation of a waterstop system is important to its efficiency and effectiveness. Most failures occur
because adequate steps are not performed.
Waterstops made of traditional rubber are often cold-spliced using specific adhesives. Thermoplastic
materials should only be used with the heat-splicing procedures. Waterstop failures are caused by weak
welds or a lack of welding, according to investigations.
Splices should be checked to ensure that they are welded through the entire profile thickness.
Prefabricated waterstop fittings can eliminate or considerably decrease leaky fittings.
Waterstops for the base is installed before the concrete is poured, and they can be set on compacted
grade, mud slabs, or vertical formwork. Because the base-seal waterstop is not embedded in the
concrete, it requires a firm substrate for initial support.
3. WATERSTOP PROFILES
Waterstop is essential for waterproofing a concrete structure, particularly joints, which are the weakest
point and are prone to leakage of water or chemical substances. To tackle these issues, waterstops are
constructed as a fluid-tight diaphragm implanted in or running along the joints.
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The waterstops are made from a variety of materials and come in several forms, profiles, and sizes,
making them ideal for various applications. There are also different types of waterstops according to their
uses and performances.
Waterstops come in a variety of materials, forms, sizes, and colors, and are suited for a variety of
applications, including moving and non-moving joints.
Here are the waterstop profiles to choose from:
FLAT RIBBED
Used for:
Construction joints with little or no movement are ideal candidates.
Feature:
The ribs efficiently boost the binding strength between the waterstop and the surrounding concrete,
while also improving the waterstop’s water sealing performance.
RIBBED WITH A BULB IN THE CENTER
Used for:
Ideal for expansion, construction, control joints, and other joints that move in a shear direction.
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Features:
Whether shear movements are lateral or transverse, the center bulb will absorb them. In general, the
larger the center bulbs are, the more movement the waterstops can handle.
Meanwhile, the ribs create a long fluid-flow path for water-proofing as well as gluing the concrete and
waterstopping together.
RIBBED WITH TEAR WEB
Used for:
Ideal for large-movement expansion joints, such as tank ring foundations.
Features:
The tear web waterstops are distinguished by their U-shaped center bulb, which tears when subjected to
large movements such as joint expansion and differential settling.
Furthermore, the ribs increase the contact surface between the waterstop and the concrete, allowing it to
grip the surrounding concrete more securely than waterstops without ribs.
SEAL AT THE BASE
Applications:
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Ideal for flat pavement construction, contraction, control, and expansion joints. They’re ideal for runways,
big containment slabs, concrete walls, and backfilled retaining walls, among other things.
Feature:
Base seal waterstops are the easiest to install and may be heated-welded with a regular splicing iron.
DUMBBELL
Used for:
Construction and contraction joints where little or no movement is envisaged are ideal candidates.
Features:
The dumbbell waterstops have the largest and thickest profile and can be used in industrial applications. It
can be heat-welded in the meantime.
DUMBBELL WITH A BULB IN THE MIDDLE
Used for:
Ideal for construction, control, and expansion joints, as well as on-grade joints at wall/slab intersections.
Features:
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Features: Able to tolerate big movements on a broad scale. This waterstop is suited for industrial
applications because of its largest and thickest profiles.
Meanwhile, a regular splicing iron can be used to heat-weld it.
SPLIT WATERSTOP
Used for:
Split dumbbells are perfect for construction joints that have little or no mobility.
Ideal for expansion moving joints on or below the slope, split ribbed.
Feature:
Waterstops with split ribbed waterstops and dumbbell-like characteristics.
CAPPED WATERSTOP
Used for:
Expansion joints with expansion boards are ideal for this product.
Features:
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The capped waterstop, which acts as a fluid-tight internal seal, is long-lasting and elegant when fitted on
the top of expansion joints.
It effectively accelerates project timetables.
4. TYPES OF WATERSTOP
The types of waterstops have their own set of benefits, uses, and drawbacks, resulting in a range of
performance. Waterstop is a waterproofing material that is often used in concrete construction joints and
deformation joints. Plastic waterstop, rubber waterstop, and metal waterstop are the three types of
waterstop available.
PLASTIC WATERSTOP
PVC and EVA waterstops are the most common types of plastic waterstops.
PVC WATERSTOP
Advantages:
High tensile strength and elasticity, great impermeability, superior acid, and alkali resistance, and
corrosion resistance are all characteristics of this material. When bonding, it’s simple to use; all you need
is a hot welding knife.
Disadvantages:
PVC is easily fragile and breaks when the temperature is too low. It is less elastic than rubber.
EVA WATERSTOP
Advantages:
Strong tensile strength and flexibility, as well as high hydrostatic pressure resistance, provide excellent
corrosion resistance and waterproof performance. In most cases, it must be machine hot welded to the
pipe or waterproof coil surface.
Disadvantages:
High cost and high hardness. Special projects usually necessitate the use of specific EVA materials. There
are only two colors available: black and white.
RUBBER WATERSTOP
Rubber waterstops are divided into two types: rubber and steel-edge waterstops.
Advantages:
High elasticity, elongation, corrosion resistance, durability, and terrain adaptability are all advantages.
Disadvantages:
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It is easy to age and loses the original waterproof performance when used for a long time. Welding can
also only be done at higher temperatures and pressures.
WATERSTOP WITH A STEEL EDGE
Advantages:
Strong adaptability to terrain changes, high elasticity, good corrosion resistance, and excellent bonding
between steel plate and surrounding concrete.
Disadvantages:
When rubber and steel edges are bonded, more care is required.
WATERSTOP MADE OF METAL
Copper waterstops, stainless steel waterstops, and galvanized waterstops are the most common metal
waterstops.
On the ground, a pile of copper waterstops is set.
COPPER WATERSTOP
Advantages:
Strong corrosion resistance; high strength, water pressure resistance, anti-seepage ability, and
deformation resistance; clear outline, no cracks, folds, or dents It’s a popular choice for towering dams.
Disadvantages:
Costly and easily damaged during construction, as well as a complicated joint welding technique. A copper
electrode is required for double-sided welding when welding.
STAINLESS STEEL WATERSTOP
Advantages:
It can be produced of various stainless steel grades depending on the application, and it has better
corrosion resistance, temperature resistance, fire resistance, and rigidity than copper waterstop.
Disadvantages:
Complex welding usually necessitates the use of embedded steel components.
GALVANIZED STEEL WATERSTOP
Advantages:
High corrosion resistance, permeability resistance, reduced displacement after installation, strong
concrete bonding, high waterproof resistance, and low cost are all advantages.
Disadvantages:
Galvanized steel sheets are prone to corrosion and aging, resulting in a reduction in waterproof
performance.
As can be observed, the performance characteristics of waterstops vary depending on the materials used.
Waterstops that are ideal for your working environment may be readily and quickly selected based on
their performance qualities.
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5. RUBBER WATERSTOP BREAKAGE IN EXPANSION JOINTS
Waterstop is a critical aspect that influences the engineering quality of expansion joints, deformation
joints, and construction joints, and it’s exceedingly tough to fix if it’s faulty. As a result, the waterstop’s
construction quality is a critical connection that influences the overall project’s quality.
6. THE RUBBER WATERSTOP CAN FAIL FOR THE FOLLOWING CAUSES:
SIGNIFICANT TEMPERATURE DIFFERENCE ARISES IN THE ENVIRONMENT
The expansion joint construction takes a long time due to the protracted construction period of large-
scale structural buildings. During this time, the temperature differential in the surroundings fluctuates
dramatically, and the concrete’s linear expansion coefficient varies proportionally as it expands and
contracts freely.
As a result, the concrete causes the liner to expand significantly. The rubber waterstop, on the other
hand, fails to respond to such deformation and causes stress concentration, resulting in the weak
component breaking.
CONSTRUCTION MISTAKES
If the rubber waterstop is not put properly throughout the construction process, air spaces will form on
the contact surface between the concrete and the rubber waterstop, causing the rubber waterstop to
become loosely bonded to the concrete and potentially peel off due to the air voids.
Large gravels in the concrete will also reach the bottom of the rubber waterstop, causing the rubber
waterstop to break owing to the force of the gravels beneath when pouring the upper layer of concrete.
The concrete is not poured at the same time on both sides of the horizontal expansion joint. The second
pouring can only take place if the previous-casting part’s concrete strength passes the appropriate
specifications. As a result, the rubber waterstop is exposed for a long time.
Steel bar binding and formwork support are required during construction, which necessitates the use of a
range of materials. If these materials are not handled appropriately, they can pierce through the rubber
waterstop, causing it to break.
SHRINKAGE OF CONCRETE EXPANSION JOINTS
Expansion joints necessitate a lengthy construction period in most cases. After pouring, the concrete
shrinks steadily as time passes.
If the concrete shrinkage surpasses the tensile stress of the rubber waterstop at a later stage, stress
concentration will occur, resulting in the weak component breaking.
All of the aforementioned factors could lead to the rubber waterstop breaking.
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7. TWO SOLUTIONS FOR RECTIFICATION OF THE RUBBER WATERSTOP BREAKAGE:
METHOD OF CHEMICAL GROUTING
It is primarily intended to address the issue of concrete expansion joint shrinkage. When solidified, the
chemical grouting material has strong adhesion qualities to concrete, as well as good elasticity and hydro-
expansibility.
For rubber waterstop fracture repair, we can utilize chemical grouting in combination with an inserted
rubber waterstop.
The following are the standard operating procedures:
Before grouting, use a steel file to remove the polyamine board, cracked rubber waterstop, and other
debris from the original expansion joint.
Wash the concrete surface to be treated from a distance of 500 mm to make it clean, level, smooth, and
debris-free;
Carry out multiple high-pressure pourings into the grouting pipe, as needed;
After pouring, apply anti-corrosion wood strips to the expansion joint surface, followed by jacked steel
plates;
Add reinforced concrete baffles and caulking fillers to the exterior surface of the wall expansion joints.
Then, around 1 meter from the top of the wall, apply chemical grouting materials to seal the expansion
joints, and connect these materials with the rubber waterstop;
When the construction is finished, keep an eye on the expansion joint width as it changes with the
temperature and the general change of the building to help with remediation quality control.
STUFFING TECHNIQUE
The stuffing method is primarily intended to address the issue of rubber waterstop breakage as a result of
poor workmanship. Asphalt hemp fiber can efficiently meet the waterproof performance of structures
because of its strong hydrophobicity, flexibility, and difficulty in extrusion.
The following are the standard operating procedures:
With a steel file, remove the damaged rubber waterstop and other debris from the original expansion
joint;
Wash the concrete surface to be treated from a distance of 500 mm to make it clean, level, smooth, and
debris-free;
Drill holes with an electric drill and pre-embed expansion bolts at predetermined intervals on both sides
of the expansion joint. The expansion bolt’s specifications will be determined by the real uneven
settlement difference. The expansion bolt must be precisely positioned and firmly pre-embedded;
For preliminary water sealing, hammer the processed asphalt hemp fibers into the expansion joint. The
depth of the filled asphalt hemp fibers must be adjusted throughout construction to achieve an excellent
waterproof effect;
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To provide a better waterproof effect, expansion rubber is preferred to cover gaps that are not fully filled
with asphalt hemp fibers. The expansion rubber surface must be level with the concrete surface, and the
gap between them must be tightly filled.
Finally, clean the concrete surface and check the expansion rubber’s flatness.
Rubber or steel plates can be put on the outside or at the bottom of the expansion joint to suit the
waterproofing requirements. The length of the plate utilized must be equal to the joint’s length. The
plate’s drilling position and spacing must be identical to the expansion bolt’s.
Waterstop is an important aspect of the construction quality of huge structures, but it is also a weak link.
As a result, it is critical to guarantee that all construction standards are met in order to assure the
project’s quality. To maintain the project’s service life, proper steps must be made to cope with rubber
waterstop breaking and provide a reliable guarantee.
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Process
Rev. Change /
Eff Date Trigger measure Prepared by Approved by
No. Improvement
impacted
1
2
3
4
5
REFERENCES:
Clause No. 7.5.1 of ISO-9001:2015
Section 7.0 of IMS Manual
************ ************
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