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METHOD STATEMENT

Method Of Statement For Pipe Laying Works

Method Statement No.


01/Rev.1

Subject : Method Statement and Quality Plan For Pipe Laying Mild Steel Pipe
Issuance Date:
16/2/2012
Effective Date:

16/2/2012

1.0 General
1) The objective of this method statement is to elaborate on the works procedure for laying mild steel pipes and its
associated works.
2) To outline preparation or coordination required before start work
3) To outline the sequence of work or construction methodology for Water Supply Works
(MSCL Pipes). Methodology start from hauling, stacking and handling of pipes, pipe
laying, road works, etc until completion of the final testing and commissioning system
and as built drawings.
4) To outline quality plan or inspection test required during project implementation.
5) To perform safe working environment and compliance to the safety requirements.
2.0 Preparation Works
2.1 Boundary/Right of ways (ROW) pegs, will be established by licensed surveyor and the Underground Utilities Mapping
(UUM) will be carried out to establish an existing underground services corridor.
2.2 The alignment of the proposed pipes, in this case 500mm pipe to Bukit Kepis Reservoir and the 800mm pipes to Bukit
Taisho Reservoir will be determined based on the information gathered from the UUM and submit to the SO for approval.
2.3 The pipe alignments will then be pegged on the ground once the SOs approval is obtained.
2.4 The relevant authorities will then be invited to visit the site to check if the pegged alignment meet their requirement.
2.5 Any relocation of underground services will be carried out prior to the commencement of the pipe laying works and the
work shall be carried out by either respective services providers or by the pipe laying contractor as a variation order work
as there is no provision of relocation of underground services in the contract.
2.6 Prior to starting of any physical works on site the Permit/Approval from the relevant authorities should be granted and all
conditions imposed by them to be strictly adhered before any construction work begins.
2.7 Access road to working place will be available for accessibility of pipe laying team and associated construction team.
2.8 All materials, such as sand, crusher run that need to be incorporated in to the works will be stockpile at strategic locations
that will not obstruct the public access and will not affect the stability of any structure. These materials will eventually be
transferred to the pipe laying location for trench filling purpose by means of dump trucks.
2.9 Temporary supports will be provided to protect all existing services.
2.10 Working platform on uneven ground will be prepared either by removal of surplus earth or backfilling with imported earth.
2.11 If required, temporary shoring may be employed to prevent damage or collapse of slope or adjacent structures or
services.
2.12 All necessary pipes, fittings, specials will be made available and strung along the pipeline routes prior to the commencing
of pipe laying works.

3.0 Hauling, Stacking and Handling of Pipes


3.1 Pipes during delivery and when in transit around the site shall be supported on three rubber covered saddles shaped to
give at least 90 circumferential support and shall be firmly held in position at each saddles by straps tightened by
turnbuckles in such a manner that the internal coating is not damaged. One saddle shall be at the center of the pipe
length and the other two shall each be positioned at a distance one-fifth of the pipe length from each end of the pipe.
3.2 Lifting of pipes on site shall be by means of reinforced canvas sling with minimum 300mm wide to protect against the
damage of the external coating. The canvas sling will be position at approximately one-fifth of the pipe length from each
end of pipe before lifting.
3.3 Pipes deliver to site shall be strung along the pipeline routes. On uneven ground the pipes will be supported on sand bags
or earth bunds which give continuous support under not less then 40of the pipe circumference. The position of support
shall be at a distance one-fifth of the pipe length from each end of the pipe.
4.0 Pipelaying
4.1 Excavation
4.1.1

Upon confirmation of the proposed pipe route as per item 2.4 above the excavation for the pipe will
commence. Excavation for pipe trench will be carried out by means of backhoe excavator or hydraulic
excavator. Excavation is closely monitored to prevent over excavation. Once excavation is completed, the
reduced level at the bottom of the trench is taken. This is required for computation of the excavated material
and for compliance to the designed pipe level.

4.1.2

At area with bad ground condition, appropriated shoring shall be provided to avoid the sides of excavated
trench from collapse and ensure safe working condition within the pipe trench.

4.2 Dewatering of pipe trench


4.2.1

At area with high water table or during raining season, dewatering pump shall be used to remove water
within the pipe trench in order to provide a workable condition for the pipelaying, welding and other
associated works within the pipe trench.

4.3 Pipe laying


4.3.1

Pipe laying will be carried out as soon as trenching is completed. Pipe to be laid will first be inspected for
damaged of external wrapping and welded ends to be wire brushed clean to remove mud/ dirt before
placing into position.

4.3.2

Pipe will be laid to the lines and levels shown on the drawings or as otherwise directed by SO. The
alignment for laying of pipes will strictly follow the alignment pegs given by the surveyor.

4.3.3

Pipe shall be lifted by using reinforced canvas sling and slowly lower down to the trench until approximately
50mm above the formation level of the trench, in the lifted position. The alignment of the pipes is adjusted
according to the requirement and the pipe mouth is brought closer to the other pipe mouth which has
already been laid. Once both pipe mouths are aligned, the lifted pipe is push toward the laid pipe by means
of excavator bucket to allow the pipe mouths to engage. Once this is done, the pipe is fully lower down and

the sling belt is removed. Recess shall be provided during the trench excavation to facilitate the removal of
sling belt.
4.4 Welding Procedure
4.4.1

The welding machines to be used for the welding of the joints will be Miller (500amp). The electrode used
will be from MOX Welding Product Sdn Bhd or equivalent. The gauge of electrodes will be 3.25mm for the
initial root run and final run of the 500mm pipe. As for the 800mm pipe the gauge of the electrodes will
be 4.0mm for both the root and final runs. The direction of the weld will be from bottom (up hand) upwards
to the top of the pipe and the completed fillet weld will be full and convex in shape.

4.5 Welding

4.5.1

Where the steel pipes are to be joined by welding it will be by means of an internal and an external
circumferential electrical arc weld at each point. For 500mm pipe, only external circumferential welding is
required base on specification. For 800mm pipe internal and external circumference welding are required.

4.5.2

Before placing the pipes together the portion of the sockets and spigot to be welded will be cleaned to a
bright metallic finish, the spigot end will then be placed in the socket and forced inside so that the spherical
surfaces are in contact and that the gap between the pipes at the end of the spigot is nowhere greater than
1.5mm.

4.5.3

Where pipes are to be joined by a steel split collar, the pipe ends and the collar will be cleaned to bright
metallic finish. The collar will then be placed on the ends of the pipe so that the space between the pipe
ends will be about 25mm from the centerline of the collar. The collar will be clamped tightly onto pipes using
the lugs and welded longitudinally. After completion of the circumferential welds, the lugs will be removed
and the longitudinal weld completed.

4.5.4

The weld will be convex full fillet type for lap welded joints made by the metal arc process using approved
types of electrodes. Each time their arc is started it will be manipulated to obtain complete fusion of the weld
metal with the pipe metal and any previously deposited weld metal.

4.5.5

Before welding is over, any previously deposited metal will be completely removed and the weld metal and
the adjacent pipe metal will be cleaned by wire brushing.

4.5.6

For 800mm pipe, air test on the joint will be carried out. 15bar of air pressure will be applied to the welded
joint for a duration of 10 minutes. Any welding defects observed will be repaired until there is no more air
leakage.

4.6 Sheathing to welded joints

4.6.1

Upon welding of joints, the bare metal at the joints will be thoroughly cleaned to a bright metallic finish and
will be immediately coated with primer solution using brush. As soon as the primer is set, the sheathing will
be completed by using Denso Tape.

4.6.2

For the internal of 800mm pipe , cement lining of mix 1:3 will be apply on all bare metal of the same
thickness with existing pipe lining.

4.7 Refilling of trench


4.7.1

Trench filling will only be carried out upon inspection by SO or his representative.

4.7.2

Suitable excavated materials will be deposited in layers and rammed into the pipe trench with suitable
shaped rammers.

4.8 Replacement of unsuitable material


4.8.1

For certain areas with bad soil condition, earth upon the trench excavation limit might need to be removed
and replaced with suitable material as directed by SO.

4.8.2

The unsuitable soil will then be excavated and cart away from site. Prior to backfilling of suitable material,
the receiving ground must be inspected and approved by SO.

4.9 Road Works


4.9.1

As the pipe alignment is mainly on the road shoulder the area of premix is only confined to the access road
into lots and the area for each excavation is small. For the premix area, upon completion of pipe laying the
trench will be backfilled with suitable granular
materials to the soffit of the sub-base which is 550mm below the top of the road. The backfilled materials
shall be compacted with suitable vibrating roller.

4.8.2

Crusher run will then be placed on the compacted pipe trench in two layers of 225mm thick and compact
accordingly . Pending on the availability of the premix from the quarry, sometime it might not be possible to
premix the excavated premix area on the same day in cases like this the crusher run will be fill to the
same level as the existing premix , and come back to redo the premix road on other day.

4.9.2

A layer of bituminous tack coat will then be sprayed across the compacted sub base and a layer of binder
course of 60mm thick will be spread manually across the sub base and compact using vibrating roller.

4.9.3

The 40mm thick wearing course will be applied at a later stage. The same procedure will be applied.

4.10Pipe cutting
4.10.1 Where it is necessary to cut pipes for closing lengths or for the pipe specials, the cutting will be neatly and
accurately performed by using suitable tools.
5.0 QA/QC Record of Works

5.1 Record for pipe laying will be logged for trace ability in a pipe-log. The pipe-log will be filled in by the site supervisor and
verified by the SOs representative. The pipe-log will contain the following information:5.1.1

Pipe-log reference no.

5.1.2

Date

5.1.3

Pipe marking

5.1.4

Pipe dimensions i.e diameter, length, wall thickness, etc

5.1.5

Location of pipe laid in chainage

5.1.6

Invert level of trench, pipes and ground level (before excavation and after backfilling)

5.1.7

Welding detail including welders name, time welding started and completed

5.1.8

Schematic of pipe joint, type of joints

5.1.9

Check box for sand filling

5.1.10 Check box for concrete surround


6.0 Water tightness test
6.1 After a length of pipeline has been completed, it will be water tight tested against stop ends. The testing will be carried out
at approximately 2 km in length in between washouts or air valves. The stop ends will be closed by approximately end
caps with sufficient strength to withstand the test pressure
6.2 The water source for the water tightness test will be obtained from adjacent water pipe line or from the stream where after
from Existing pipe line is not available. If stream water is taken, it will be free from silt, contamination and pollution and
agreed by SO.
6.3 Generally, the pipe stretch to be test is fully filled with water. Upon filling up the pipeline, it will be left for 24 hours for
absorption of water by the cement lining to take place. During this period, inspection will be carried out at all flexible joints.
Ay leakage at these joints will be rectified immediately. Upon completion of rectification an lapse of 24hours since the
pipeline is completely filled up whichever later, gradually increase the pressure within the pipe using a pressure pump to
the desire testing pressure. Rectified the flexible joints if any leakage found. If no leakage found, proceed with the test by
monitoring the pressure gauge for 24 hours. After 24 hours, reinstate the pipe pressure to the testing pressure. Measure
the volume of water used for reinstating the testing pressure. This volume of water will represent the volume of water
leaked through the pipe during the 24hours. If the leakage does not exceed 0.05 liter per mm of internal diameter per 24
hours per kilometer of pipeline, the line is deemed to have passed the water tightness test.
6.4 Detail method statement for water tightness test for each stretch of pipeline to be submitted separately for SO approval
prior to the actual water tightness test at site.
7.0 Sterilisation and Flushing of Pipelines
7.1 Upon completion of pressure testing, cleaning and connection of the pipe to the outlet at Kuala Jelai Water Treatment
(WTP)plant to the respective reservoirs the sterilization of the pipes can commence. The sterilizing agent to be used for
the sterilization will be calcium hypochloride(CaHCl) of 65% concentration. CaHCl solution of 20mg/l concentration (pre

mixed) will be injected into the pipe via the airvalve tees at predetermined location to achieve maximum utilization. Once
the CaHCl solution is injected into the pipe all the airvalve will be installed backed to the tees. The pipe will be filled with
water from the WTP. Once the pipe is filled the valve at the WTP will be closed and left for 24 hours. An inspection of the
pipeline will be carried out to ascertain that all the valves are closed. The water samples will be taken after 24 hours,
should the sample shown a chlorine content of 0.2ppm then the pipeline is considered sterilized. The process will be
repeated until 0.2ppm is achieved.
7.2 Upon the completion of part 7.1 above the flushing of the pipes can commence. The scour valves discharge directly into
water courses will be open fully to flush the pipe until the water is clean.
7.3 The water for Sterilisation & Flushing will be provided free of charge.

8.0 As built drawings


8.1 Upon the completion of the works the as built drawings will be prepared. As the alignment will in most cases followed the
peg pegged by the licensed surveyor, the other information that required for the pipeline as built drawing is the as built
invert level of the pipe. This information will be recorded on the Daily pipe log and will be pass to the licensed surveyor
for their preparation of the as built. The Surveyor will prepare the drawing based on the pipe log and also carried out field
survey for the works.
9.0 Safety measures
9.1 Workers should wear appropriate personal protective equipment (PPE)
9.2 Swing area of heavy machinery to be monitor closely.
9.3 Checking of wire rope, webbing sling and tools are in good working condition.
9.4 Adequate lighting if working during nighttime.
9.5 Excavated pit/ trench will be inspected by supervisor to ensure safe working environment prior to any further works within
the pit/ trench.
9.6 Open trench will be properly barricaded.

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