7 external utilities

Buildings Practice For ProfessionalsConstruction Method Statements

Chapter 7 External Works & UtilitiesSafety General

1 Refer to Chapter 3, MS 12 & 13, Chapter 4, MS1, Chapter 6, for general provisions on safety discipline in addition to those included with various method statements on this Chapter

2 Relevant point should be extracted from description in line to requirements on relevant activities

3 It is to be noted that safety standards vary from organization to organization, company to company & client to client

4 Just consideration of economy on project cannot exclusively, be a criterion to avoid or reduce safety measures

5 A minimum level of safety measures installations should be made a ‘must’ for a site supervise to ensure that workforce ‘must’ work safely

6 It is preferable to work with acceptable level of safety rather than loosening lives of workers External Works & Utilities

MS1Placing concrete on service water tank foundations

IndexScope/Safety/Method/Equipment/Attachment

Scope1 Purpose of this method statement is to define sequence and methodology for placing of

concrete on service water tank foundations.

Reference documents1 Specification

Safety & Responsibilities 1 Refer to safety general description on page 1

Method1 Preparatory works shall be carried out for formworks in circular profile, for which due

provisions should be made for specialist form. 2 This form shall be well supported & anchored to resist expected forces during pour. 3 As a parallel activity, reinforcing bars shall be placed & fixed in correct positions, duly

inspected.4 It is proposed to cast Ring beam in two pours. 5 Stop end forms shall be placed at opposite locations across full width and depth, to

establish construction joints. 6 Concrete shall be poured onto section in one go 300 to 450 mm high around and

compacted with suitable vibrators. 7 Care shall be taken to ensure that concrete is placed and compacted in its final position,

within time permissible form time of batching to time, it should be compacted in accordance with concrete production specification, which may be generally 1 to 2 hours.

Page 1 of 71 2012 Int. P Eng (India) Suraj Singh


Chapter 7 External Works & Utilities8 Concrete delivery shall be planned accordingly, to quantity & duration of pour, to enable

a smooth concreting operation. 9 Concrete shall be continually poured from start to concrete pour finish. 10 No cold joint shall be allowed to form & all flash setting of concrete should be avoided

by water spraying on forms & reinforcing bars so that both items are keep temperature lower than air temperature.

11 Proper concrete vibration shall be effected using needle vibrator. 12 After concrete is completed, proper method of curing shall be carried out & continued for

specified number of days. 13 All tests for onsite concreting shall be conducted by RMC laboratory staff duly recorded.14 QC inspection shall be conducted for all activities

Equipment1 Concrete pump, concrete trucks, vibrators,

Attachment1 None

MS2Structural steel pipe racks

IndexScope/Reference documents/Definitions/Responsibilities/Safety/Method/Equipment

Scope1 Purpose of this Method Statement is to define sequence and methodology that shall be

implemented for Erection of steel structure pipe racks.

Reference Documents1 Specification Grouting2 Specification Steel Structure Fabrication3 Specification Painting4 Specification Galvanizing5 Specification Project Preservation and Export Packing6 Relevant IFC drawings

Safety & Responsibilities Refer to safety general description on page 1

1 Use of cranes shall be assessed and all safety regulations enforced.2 Men working at height shall be equipped with required personal safety equipment such as

body harness, coveralls, safety glasses, hand gloves etc.3 When, man lift is used for high level working for personnel, respective measures shall be

adopted in this regard

MethodMaterials Receivables

1 All Structural steel material to be used for permanent works shall be received on site in appropriate lay down area.

of 71 2012 Int. P Eng (India) Suraj Singh


Chapter 7 External Works & Utilities2 All items shall be inspected to conduct a check of delivery against necessary shipping

documents. 3 All structural steel members shall be checked for quantity, quality and identification.4 Then all materials shall be properly stored and protected.

Concrete Foundations1 Surface of concrete foundation shall be prepared in accordance with specification, to

receive grout.2 All concrete foundations on which, steel structures are to be erected shall be released by

QC department upon completion of civil activity.

Fasteners (Bolts, Nuts & Washers)1 Upon receipt on site of fasteners, a minimum of one sample (1bolt, 1 nut & 1 washer)

shall be selected and tested by an independent laboratory to confirm specification conformance.

Assembly of Grid Frames1 Material for necessary grids shall be placed near to area of erection. 2 This shall be carried out using a suitable trailer & a 50 ton crane.3 Grid frames for both rows (A&B) shall be assembled. 4 All bolts, washers and nuts shall be fitted, fastened and tightened.

Erection of Columns\Grid Frames1 Stainless steel shim plates to correct thickness approximately 25mm, shall be placed at

center of foundation column between holding down bolts. 2 Shim plates shall be retained in position permanently, by surrounding with mortar to

avoid shim displacement during erection of columns. 3 Shim placed on foundation shall be embedded in mortar bed, such that top of shim is

level in all planes. 4 Grid frames shall be installed, leveled and plumbed on foundation bases. 5 Stay ropes shall be provided to maintain stability, until such time, when horizontal

members are connected. 6 Stays shall be secured to purpose made anchor plates attached to adjacent foundations. 7 Foundation bolts shall be only hand tightened. (Necessary tightening or torque

application shall be done later, after grouting). 8 Horizontal members and bracings that interconnect these grid frames shall be assembled

and erected.9 Assembly of Verticals and Horizontal members shall be in sections. 10 On completion of each section with all bolts and nuts in place and tightened, final level

and alignment shall be checked and inspected.

Grouting1 After structural steel frame assemblies have been inspected by QC department,

application of grouting shall be carried out inline/according to Specifications & manufacturer’s instructions.



Chapter 7 External Works & UtilitiesEquipment

1 Crane 30Ton\50 Ton2 Flat Bed Trailer to transport fabricated members to location at site3 Fork lift – for minor movement of steel members4 Guy ropes and tensioning equipment5 Man baskets, whenever required6 Scaffolding (Movable & Non movable Types)7 Air Compressor8 Impact Wrench9 Welding Generator( if required)10 Gas Cutting Equipment (if required)11 Portable Grinding Machines12 Portable Drilling Machines

MS3Water tightness tests for collection sumps

BS 8007:1987 Section 9IndexScope/Reference documents/Safety/Method/Equipment/Attachment

Scope 1 This statement is aimed to present proposed procedures (Typical) that shall be adopted to

conduct water tightness tests for following water retaining structures. 2 Collection sump 70-TB-201 Utilities East3 Collection sump 70-TB-202 Ethylene 4 Collection sump 70-TB-203 Utilities East5 Collection sump 70-TB-205 Utilities South

References1 Specification, Clause 7.0, Crack Control


MaterialsWater requirements

1 For 70-TB-201 370 cum and 5 % for stabilization period2 For 70-TB-202 237 cum and 5 % for stabilization period3 For 70-TB-203 166 cum and 5 % for stabilization period 4 For 70-TB-205 191 cum and 5 % for stabilization period

Method (sketch # 9)1 Structure to be tested shall be completed of all RCC constructions inline/according to

specified and agreed procedures. 2 Complete filling of tie rod holes with MBT Master Flow 544 shall be carried out

inline/according to manufacturer’s instructions



Chapter 7 External Works & Utilities3 70-TB-201/202/203 Inlet pipes 600 mm dia. and for 70-TB-205 inlet pipes 450 and 400

mm dia. shall be laid in place to levels shown on drawings, as reflected on water quantity schedule i.e. Invert levels at maximum supply elevations.

4 External surfaces of structure shall be prepared & applied with specified protective system Bitustick XL, Polybit

5 Civil Contractor QC Inspection shall be conducted for approval of membrane6 Structural backfilling shall be carried out externally, to project specifications & necessary

field density tests conducted to requirement 7 Application of floor screed as specified shall be carried out8 Some engineers allow structural backfill externally & application of protective coating

prior to conducting water tightening test.9 But, water tightness test should be considered without carrying out backfilling &

application of any coating system for accurate assessment as well as, compliance with tanking technology/codes

10 Entire surfaces of structure to be tested shall be sweep blasted removing all loose spalls, dust dirt etc.

11 Prepared internal surfaces shall be inspected by Civil Contractor QC for approval12 Following operations shall be involved to conduct water tightness test inline/according to

BS 8007: 1987 Section 9.1 applicable to liquid retaining structuresa A graduated stick shall be provided on wall top to show water levels to a’ mm’ count b Potable water shall be filled into respective sump pit structure at a rate 2 m per 24 hours,

for which, attached ‘filling scheduled quantities’ shall apply (refer to schedule planned for test).

c After water is filled into required level, it shall be allowed to stay for a period of 7 days for stabilization, absorption and autogeneous healing.

d If so required, water shall be added to maintain maximum test level in case, it is lost during this period.

e Test shall commence from 8th day and continue for 7 days for a design crack width of 0.1 mm according to specification requirement.

f Observations regarding water level drops, shall be recorded every 24 hours by visual measurements on mm scale

g Test records shall be documented on attached form QCF h ‘STRUCTURE LEAK TEST ‘and judgment on test made accordinglyi During this 7 days period total permissible loss in level, shall not exceed 1/500 of average

water depth of full tank or 10 mm.j After test is successfully completed, water shall be pumped out either to other structure

for testing, should that be ready to receive it or if not, to other construction areas for curing or some other purpose, as agreed leaving pit empty.

k In this case, structure is roofed by RCC, which does not pose any considerable chance for water loss by evaporation.

l This fact should be considered, while assessing total loss in level calculated or observed being loss due to evaporation plus loss due to leakage

Remedial Work, if required1 In case of unsatisfactory performance of water tightness test and upon agreement with

EPC Contractor/Engineer, injection grouting method may be adopted to seal seepage routes, which must be marked based on inspection during leakage.



Chapter 7 External Works & Utilities2 Should structure not satisfy 7 days test then after completion of remedial work, it should

be refilled and if necessary, left for a further stabilizing period as conducted earlier, for a further test of 7 days’ duration must then be undertaken in accordance with specification or code clause.

Schedule /plan for proposed water tightness test

S # Description of operation Number of days

Remark

1 Filling potable water in sump pit 1m deep below base level of catch pit and 1 m depth above base slab to make a total depth 2 m

1 By tankers filled at a uniformRate not greater than 2 m in 24 hours

2 Filling potable water to another 2 m depth to make 4 m

1 By tankers

3 Filling potable water to remaining depth to maximum supply level

1 By tankers

4 Stabilization period to allow for absorption and autogenous healing

7 Additional water to be filled if required

5 Testing period to record water loss by seepage and by evaporation every 24 hours

7 Monitoring regarding seepage loss and provision of 1/500 of average depth or 10mm. (Visual inspection)

6 Pumping filled water out offsite 1 To other structure for test7 Total period of water Test 18 Days

Post water tightness test1 MBT shall produce a representative Masterseal 550 coating sample for approval by EPC

Contractor and client. 2 Internal surfaces shall be coated according to approved sample3 External surfaces shall be provided with waterproofing/concrete protection membrane in

line/according to requirement 4 Civil Contractor QC inspection shall be conducted to approve applied coating5 Structural backfilling shall be carried out externally, to project specifications & necessary

field density tests conducted to requirement 6 Application of floor screed as specified shall be carried out

Equipment1 Water Tanker, Pump, sweep blasting package etc.2 Graduated stick, compactor

Attachment1 Water quantity schedule

MS4Concrete coating using master seal 550

IndexScope/Reference documents/Definitions/Responsibilities/Safety/Method/Equipment/ Manpower/Attachment



Chapter 7 External Works & Utilities

Scope 1 This statement is aimed to present proposed procedures that shall be adopted to apply

specialist material for concrete protection on internal surfaces as specified.

References1 Collection sump Utilities East2 Collection sump Ethylene 3 Collection sump Utilities East4 Collection sump Utilities South

Drawings 1 Not included

Specifications 1 Master seal 550-product data sheet

Safety & Responsibilities Refer to safety general description on page 1 & in addition

1 Barricades, markers and night lights etc. shall be arranged as required.2 Only tagged scaffolding with guardrails, foot rails etc. shall be used to afford access to

high locations. 3 Material shall be used in well ventilated area and inhalation avoided.4 Personnel shall use protective clothing, gloves, eye protection, masks etc. to avoid skin

contact.5 Plenty of clean water shall be made available.6 Immediate medical attention shall be imparted with, when so required7 All first aid facilities shall be provided near to site locations

Storage1 Material shall be stored under cover out of direct sunlight and protected from temperature

extremes. Product shelf life is 12 months, subject to proper storage2 Care shall be taken during use and storage to avoid contact with eyes, mouth, skin and

foodstuffs. 3 Containers shall be resealed after use. 4 Immediate, medical attention shall be called for, in case of some adverse effect/impact on

to some personnel handling this product5 Damaged tins shall be disposed off according to meeting requirements by state

regulations.

Materials1 Coating, Masterseal 5502 Master seal 550 is a two component acrylic modified cementitious coating that requires

only site mixing to form an ideal product to waterproof and resurface concrete, masonry and most other construction materials.

3 Simply applied by stiff brush, roller or trowel it forms a waterproof, flexible coating providing an effective barrier to waterborne salts and atmospheric gases ingress.




Method (sketch # 9)Method involves following sequences in general.

1 Surface preparation 2 Mixing3 Application

Details1 All grease, oil, dust, residual curing compound, mould release agent or other

contaminants, which could impair adhesion, shall be removed from surface by degreasing and washing.

2 Whole surface to be coated shall be cleaned using water jetting and visually inspected to ensure that roughness does not exceed equivalent to grade 80 sand paper.

3 All holes, voids, depressions, spalls etc. shall be filled with Masterseal 550 mixed to a trowel consistency, scraped lightly into surface, allowed to dry and later roughened by hand wire brush on small areas and gently water jetted on larger areas.

4 Filled areas shall be visually inspected to ensure that correct mechanical key is achieved.

Mixing1 Master seal is supplied in pre measured units and shall be mixed on site using clean

containers. 2 Powder shall be slowly added to liquid component and agitated/mixed for 2 minutes by

using a slow speed hand power drill, fitted with a suitable paddle attachment, until a homogeneous lump free consistency is obtained.

3 Mix quantity shall be such that it could be consumed in one hour during application without allowing any re tempering with water.

Application1 Coverage 1.8 KG/SQM at 1 mm thickness2 Coating shall be produced 1mm thick applied in one coat3 In hot weather, surface to be coated shall be shaded from direct sunlight. 4 Areas to be coated shall be saturated with fresh and clean water.5 Prepared and saturated surface shall be inspected by Civil Contractor QC followed by

EPC Contractor/Engineer approval6 Mixed material shall be applied, while surface is visibly damp without standing water,

using short stiff brush or roller. (Roller shall be used in major/large areas)7 Evenness and thickness of applied coating shall be regularly checked during application,

while material is still wet.8 Materials shall be allowed to dry and visually inspected 9 Civil Contractor QC inspection shall be conducted followed by EPC Contractor/Engineer

approval10 All missed areas shall be saturated and then touched up.

Equipment1 Water tanker with water jetting arrangement2 Hard brushes for minor areas



Chapter 7 External Works & Utilities3 Clean container4 Slow speed drill with paddle attachment5 Stiff brush/Roller

Attachment1 Masterseal 550 Data sheet and statement

MS5Backfilling of west side of quench tower foundation (rib)


Scope 1 This statement is aimed to propose procedures to be adopted for construction of west

direction extended part of design foundation/Cantilever rib.

ReferencesDrawing

1 Revised IFC drawing was received, after completion of blinding concrete and Rebar binding works.


Method1 Extended part shall be constructed to following sequences.2 Concrete shall be poured to preparatory works carried out on site.3 De shuttering shall be done after 14 days inline/in conformance to specifications.4 Application of membrane to underside/soffit of slab.5 Backfilling underside space by lean mix PBFC 20 grade concrete.

Details1 Since, all preparatory works, such as bending and binding of reinforcement, centering

and shuttering of form work, propping etc. and all relevant activities, have been carried out to design requirement per previous revision/ according to project specifications, concrete shall be poured to works done.

2 After completion of pour, sequential curing and a lapse of 14 days, forms shall be struck from underside of slab/soffit

3 Formed surface shall be applied with protective concrete membrane, as specified and shown on sketch

4 Space left between soffit and prepared ground shall be prepared for concrete filling by erecting formwork in letter box style

5 Forms shall be fabricated according to following descriptions6 Bottom panel of 600 mm height shall be erected around 7 Top panel of 200 mm size shall be prepared in letter box style to allow pour of concrete8 Top panel post pour shutters shall be made ready, before commencement of concrete



Chapter 7 External Works & Utilities9 Immediately, after pour reaches to brims/soffit level, top panels shall be placed in

position to close all external surface and supported to requirement10 Forms shall be struck after lapse of number of days required per project specification

Equipment1 Concrete Pump2 Concrete Transit Mixers

Attachment1 Sketch

MS6Excavation cooling water outfall chamber


Scope 1 This statement is aimed to present proposed procedures to be adopted to carry out

excavation for foundation in respect of Cooling Water Outfall Chamber.

References1 Drawing 2 Specification Excavation & Backfilling for Underground structures


Design Status1 Centre lines of proposed structure and coordinates meet at N (Typ) and E (Typ)2 Plan size of chamber is 10.025 m x 7.2 m3 Excavation has to be carried out to +2.3 m level from RGL +10.500 i.e a depth of 7.8 m

shall be excavated

Method (sketch # 19)Excavation shall be carried out to following sequences

1 Setting out lines2 Barricading area3 Excavation in stages, as shown on sketch

DetailsAttached sketch

1 To start with, a surveyor shall set out site for excavation to exact lines and coordinates references.

2 After setting out, excavation lines shall be marked 4750 mm away from proposed external faces of structure, as shown on sketch.

3 Excavation shall be carried out to details shown on sketch in 5 steps of size 750 mm tread and 1500mm riser and bottom step of 675 mm riser.



Chapter 7 External Works & Utilities4 Size of lowest level excavation shall be 12025 x 9200 mm and that of top 19525 x 16700

mm.5 Excavation shall be started from one end and top 750 mm deep be completed6 Access shall be ramped for equipment to enter.7 Excavation shall be carried out in strips of 750 mm depth, until whole earth mass is taken

out.8 Excavated earth shall be transported to stockpiles immediately, keeping site tidy.

Equipment

1 Excavator2 Dumper

Attachment1 Sketch

MS7Drilling of holes on pipe rack & structures on site


Scope1 Purpose of this Method Statement is to define sequence and methodology, that shall be

implemented for drilling of holes on structural steel members, which have been erected and requires drilling of holes due to manufacturing error on location or design change, after beams have been primed or finished coated.

Reference Documents 1 Specification Steel Structure Fabrication2 Specification Painting3 Specification Galvanizing4 Specification Structural Steel Erection5 ANSI A 10.13 Safety Requirements for Steel Erection6 Relevant Drawings

Safety & Responsibilities Refer to safety general description on page 1& in addition

1 Use of cranes or man lifts shall be assessed and all safety regulations enforced.2 Men working at heights shall be equipped with required personal safety equipment.3 Only competent personnel shall be engaged to carry out operation

Safety Supervision1 A competent inspector shall visit area daily to assess safety measures adopted. 2 Snag observed during inspection shall be notified to supervisor present, who must

immediately, act to bring safety measures to an acceptable standard 3 CM shall plan and resource drilling of holes, in accordance with this method statement. 4 Construction Superintendent shall monitor these activities, directing workforce as

necessary.



Chapter 7 External Works & Utilities5 Erection Foreman shall control workforce ensuring full implementation of this method

statement including safety measures.

Method1 New location of holes’ centre on specific member item, shall be marked per details on

updated drawing or drawing revision.2 Using a drilling machine, preferably a magnetic base drilling machine, a pilot hole of size

8mm or 10mm diameter shall be initially drilled. 3 These holes shall be subsequently, drilled to specified diameter.4 Area around holes shall be cleaned, burrs removed and edges rounded off. 5 This shall be affected by either using emery paper or grinding wheel.6 Bare surfaces should made dust free and cold galvanizing applied as a coat with ‘Jotun

Barrier 86’, a two pack zinc rich epoxy primer .7 Allow about 4 Hours for drying.8 Make necessary touch ups using same grade & colour, which were used to apply paint on

structure prime coat and top coat, if necessary.

Equipment1 Drilling machine2 Man lift3 Scaffolding if required4 Grinding machine

MS8Welding of earthing lugs on east west pipe rack



implemented for welding of Earthing Lugs on columns of East West Pipe rack steel structure.

Reference Documents 1 Specification Steel Structure Fabrication2 Specification Painting3 Specification Galvanizing4 Specification Structural Steel Erection5 Drawing No. (Also Refer E-Mail of 6\11\99) - Attached for Reference


Method1 Location of Earthing Lugs on respective columns shall be marked off.



Chapter 7 External Works & Utilities2 Approximate 30mm of surrounding area shall be cleaned to remove primer and

galvanizing.3 Lug shall be initially tack welded to column and then fully welded to required fillet size.4 Fillet weld shall be cleaned and free of defects.5 Welding shall be done according to approved WPS using duly qualified welders.6 Visual inspection to be conducted/done prior to surface finish.7 Surface shall be inspected prior to cold galvanizing and painting. 8 Bare surfaces should be made dust free and cold galvanizing applied as a coat with ‘Jotun

Barrier 86”, a two pack zinc rich epoxy primer.9 Allow about 4 Hours for drying.10 Make necessary touch ups using same grade & colour, which were used to apply paint on

structure prime coat and top coat, if necessary.

Equipment1 Welding Machine2 Grinding Machine

Attachment1 Drawing # 2 Copy of E-Mail (indicating location of Earthing Lug)3 PQR # 4 PQR # 5 WPS # 6 WPS #

MS9Filling around all GRP pipes within plant area


Scope1 This statement is aimed to propose procedures to be adopted for filling around GRP pipes

within Plant Area. Reference Documents

1 Specifications


Method (sketch # 20/21 indicatively)1 Following activities shall be involved to fill around pipes laid within plant area2 Fill sand with 150 mm thick layers around laid pipes3 Fill approved red fill material in layers in remaining trench space with 150 mm thick

compacted layers




Details1 First layer shall be filled 200 mm approximately compacted to 150 mm thickness. 2 Field density test shall be conducted for 95 % compaction. 3 A portion of compacted material 150 mm thick from radial area shall be removed to

replace with sand circumferentially.4 This sand shall be placed in first layer portion to replace filled material circumferentially.5 Structural fill material for second layer shall be placed in 200 mm thick compacted to 150

mm for 95 % field density and tested inline/according to specifications.6 Again, a portion of compacted material 150 mm thick from radial area, shall be removed

to replace with sand circumferentially.7 Sand shall be placed in second layer portion to replace filled material circumferentially.8 Similarly, succeeding layers of fill material shall be placed in 200mm layer thickness

approximately, compacted to 150 mm thickness inline/according to specifications and replaced by sand filling as aforesaid, until apex level of pipe is covered with sand.

9 Principle behind replacement of fill material by sand indicates that pipe should be in touch of sand

10 Remaining strata up to ground level/required level shall be filled in, with fill material in 200 mm thick loose layer approximately, compacted to 150 mm thick layers inline/according to specifications.

Equipment1 Compactor

Attachment1 Sketch showing various stages of filling

MS10Pre casting manholes/catch basin/valve chambers


Scope1 This statement is aimed to propose procedures to be adopted to precast manholes, catch

basins and fire water main valve box (wherever, so required to be used precast) chambers and install in specified prepared locations.

Reference Documents 1 Drawings related to manholes, catch basins & chambers2 Specifications


1 Safety precautions required, while working on excavations, mass concrete, forms, reinforcing bars, concrete pouring, concrete protection etc. etc all according to acceptable standards, shall be strictly adhered to on operations concerned



Chapter 7 External Works & Utilities2 Adequate safety shall be observed during lifting and offloading precast concrete covers to

relevant locations to avoid mishaps by observing regulatory crane fitness requirement and validity of permit to work.

3 Only competent personnel shall be engaged to carry out operation4 Crane and trailer operators shall abide by all traffic rules, while carrying out operations

and if so required, a banksman be engaged to direct movement5 Crane shall not be operated during inclement weather conditions with dust storms6 Adequate safety measures shall be adhered to during lifting and offloading precast

foundations to relevant locations avoiding any mishap by observing regulatory crane fitness requirement and validity of permit.

7 Crane and trailer operators shall abide by all traffic rules while carrying out operations and if so required, a banksman shall be engaged to direct movement

8 Crane shall not be operated during inclement weather conditions with dust storms

Method (sketch # 10/31-40 indicatively)Following activities shall be involved:

1 Prepare a pre casting yard on site2 Fabricate form works according to design details3 Fabricate box outs to be used in forms4 Fabricate reinforcement5 Place reinforcing bars and noncritical cathodic protection6 Cast bases with a kicker and shear key as shown in first stage and cure7 Scabble kicker to roughen construction joint surface 8 Cast walls with pipes inlet and outlet boxes, formed in second stage with lifting hooks9 Cure cast units10 Cast cover slabs in third stage and cure11 Excavation at relevant area/s12 Blinding and membrane13 Transportation of completed open units to locations14 Installation of units on correct alignment and levels15 Inspections by Civil Contractor QC and EPC Contractor approval16 Prepare cover slab bearing mortar bed as specified17 Provide box out sleeves for steps insertion18 Pipe laying by others19 Install seals around pipes and box out concrete 20 Cast surrounding concrete 150 mm thick as specified21 Apply 1 mm thick coal tar epoxy on external surfaces as specified22 Bench invert levels between pipe flows, where specified23 Inspections by Civil Contractor QC and EPC Contractor approval24 Plug pipe spigot ends 25 Place covers

Details1 A precast yard having a capacity of about 20 units, as shown on attached sketch shall be

used for pre casting operations 2 Yard shall have convenience for vehicles to freely move for various activities3 Strong platforms of 100 mm thick concrete shall be used as casting bases/floors



Chapter 7 External Works & Utilities4 In one go, about 10 units shall be made ready for bottom slab pouring5 Overlap shall be provided from top of kicker as specified and if so convenient,

reinforcing bars shall be fabricated continuously6 Formwork for base slabs with kickers to be cast monolithically, shall be prepared

according to typical sketch attached7 Required reinforcing bars shall be placed in correct locations with 75 mm covers/spacers8 Shear key forms shall be erected according to details and well clamped in9 Civil Contractor QC inspection shall be conducted followed by EPC Contractor approval10 Concrete shall be poured through a chute11 Curing shall be carried out by spraying compound and later, by saturated hessian and

polythene cover12 Wall formwork shall be fabricated on site using marine ply 13 Internal forms shall be fixed first to correct dimensions14 Box outs shall be fixed to required locations on fixed forms15 Reinforcing bars for walls as well as, trimming around box outs shall be placed in

position16 External forms shall be fixed around, well supported, in plumb and ensured to correct

dimensions17 Lifting lugs shall be placed in required locations in walls using 16 mm dia. rebar

according to detailed sketch attached18 A binding wire length shall be tied to horizontal reinforcing bars in continuity, connected

to boss fixed near wall top for cathodic noncritical arrangement/connection19 Civil Contractor QC inspection followed by EPC Contractor approval20 Pouring concrete into wall forms with wood float top surface finish and curing by

compound, later by hessian and polythene cover for specified period21 Forming cover slab shutters according to specified details 22 Forming cover box out shutters into required position23 Placing reinforcing bars into correct positions24 Fixing cover lifting hooks according to details attached25 Civil Contractor QC inspection followed by EPC Contractor approval26 Pouring concrete and curing as aforesaid27 Inserting steps shall be carried out by fixing pieces into preformed holes in concrete walls

as created by box sleeves with approved grout at a stage, when concrete has gained sufficient strength

28 Excavation shall be carried out to specified level and alignment followed by blinding and waterproofing

29 Open precast chambers shall be crane lifted and transported by a trailer to relevant locations followed by offloading into correct alignment

30 Pipes shall be laid in line to requirements & tested accordingly by relevant team31 After pipes are laid, specified seals shall be placed in with surrounding concrete as well

as, box out void forms erected, followed by concrete pouring into box out voids and plug (concrete surround)

32 Benching wherever specified, shall be formed according to channel flows and details33 Bedding of joint 20 mm thick, shall be carried out on site as specified34 After levels and alignment are ensured, cover slab shall be correctly placed in, followed

by formation of concrete block work pad to suit cover elevation



Chapter 7 External Works & Utilities35 Cover shall be set in, on block work pad, using cement sand mortar36 Mass concrete shall be laid around cover as specified37 External surfaces shall be applied with 1 mm dry film thickness, non solvent coal tar

epoxy in accordance with project specifications38 Civil Contractor QC inspection conducted followed by EPC Contractor/Engineer

approval39 Whole levels and alignment details shall be documented according to requirement

Equipment1 Crane/Concrete Transit mixer/Trailer/Vibrator

Attachment1 Yard layout2 Kicker details3 Sketch showing lifting hooks for unit walls and base4 Sketch showing lifting hooks for cover slab

MS11Termination detail to protective membrane around RCC columns

supporting structural steel columns for pipe rackscase (1) with aluminum bead

case (2) with rebatecase (3) gravel fill

case (4) pavingIndexScope/Reference documents/Definitions/Responsibilities/Safety/Method/Equipment/ Manpower/Attachment

Scope 1 This statement is aimed to propose procedures to be adopted to clamp in, waterproofing

membrane termination using Aluminuum Beads around column sides to substitute formation of conventional rebate, partly for pipe racks foundations, other structures and for other areas, such as hard/soft landscapes.

References1 MAR (Site fixed sample approved)


1 Personnel shall use PPE (gloves, masks, eyeglasses etc.) 2 Use of barrier cream to protect skin from adverse effect of sealant shall also, be made.3 Material safety datasheet shall be referred to for disposal and for all further information. 4 A safety inspector shall visit site everyday and instruct supervisor in case, some snag is

noticed, who must immediately, implement instructions




Materials1 Aluminum Bead lengths to Sectional dimensions 30 mm x 2 mm2 Screws 3 mm dia.3 Sealant-Polyurethane-Gun Grade Cold seal 200PF for horizontal usage on Aluminum

strip (Manufacturer BCR) (Emirates Specialties) or equivalent

Method (sketch # 7)Following operational sequences shall be involvedCase 1

1 Concrete surface shall be cleaned of all dirt & dust using a brush2 Application of waterproofing membrane to defined levels, keeping top 200 mm or

variable dimension conforming to details on drawing, above finished ground level3 Lines shall be marked on all sides to correct level per drawing4 Bead Lengths to exact site dimensions shall be cut to suit a close fit between ends5 Every bead shall be provided with a minimum 3 # screws to be drilled and fastened into

concrete penetrating membrane, using an electrical operated Drill 6 After screws have been fastened and beads are in proper alignment, approved sealant

shall be applied to top of bead keeping about 5 mm above bead, with a down ward lap as follows

7 Sealant shall be applied using a gun, fitted with conical nozzles, adjustable to suit width into corner, using an even trigger pressure & cleaning nozzle occasionally to avoid contamination.

8 A smaller timber spatula, soaked in soapy water shall be used to compact sealant into joint/junction for a smooth polish finish formation.

9 Mixing and application equipment shall be cleaned immediately, after use10 Civil Contractor QC inspection shall be conducted & relevant ITP signed off

Case 21 Where grooves have already been chased, waterproofing membrane shall be tacked in &

sealant applied to space left in groove according to specifications and manufacturer’s instructions.

2 No Aluminum bead shall be used in this case.3 Sealant shall be applied around bead continuously4 Civil Contractor QC inspection shall be conducted & relevant ITP signed off

Case 31 In gravel or soil area, membrane shall be terminated at a level ‘50mm plus’ below footing

top level keeping Aluminum bead details typical. 2 All other details shall remain as in ‘case 1’ if no rebate has been chased3 Civil Contractor QC inspection shall be conducted & relevant ITP signed off

Case 4 1 In paved area, membrane shall continue upto termination level, but protection board

cease at 20 mm below paving level, filled with mastic on top, keeping all other details as in ‘case 1’ if not chased for rebate



Chapter 7 External Works & Utilities2 Civil Contractor QC inspection shall be conducted & relevant ITP signed off

Equipment 1 Electrical operated drill 2 Sealant applying gun

Attachment 1 Sketches 2 Case wise description

MS12Road crossing for laying 1 # 20” raw ethane/1 # 6” propane to

identified locationsIndexScope/Reference documents/Definitions/Responsibilities/Safety/Method/Equipment/ Manpower/Attachment

Scope1 This statement is aimed to propose procedures to be adopted to carry out excavation at

road crossing to facilitate laying pipe lines 1 # each 20” Raw Ethane and 6” Propane at location identified on attached drawing to following references

Safety & Responsibilities 1 Refer to safety general description on page 1 & in addition2 In this case, excavation has to be carried out on Operating Authority area therefore all

regulated precautions shall be strictly adhered to effect ‘full safety standard’ applicable to works carried out in plant operation controlled areas for excavations & road crossings particularly.

Safety Supervision 1 In case of incident, where utilities ‘not identified’ are discovered or damaged, all work

shall stop in area and Operator Shift Controller and HSE department immediately notified.

Method (sketch # 18/20 indicatively)Instance 1

1 Asphalt shall be removed2 Hand excavation shall be carried out to expose cables & other services by seaming area

with detectors3 After exposure, all cables shall be covered with split PVC pipe to continue excavation

mechanically 4 Remaining portion of trench shall be excavated by machine5 Preparation of trench to lay RCC pipe sleeves shall be carried out6 Bedding material shall be laid to receive pipe sleeves7 Pipe sleeves with dia. 8 “ more than specified respective pipes dia. shall be laid to design

alignment and levels 8 Filling over pipe sleeves shall be carried out to specifications



Chapter 7 External Works & Utilities9 Diverted services shall be reinstated10 Backfilling up to road formation shall be carried out to specifications11 Above similar operations shall be repeated for Instance 212 Central verge shall be made good & diverted services reinstated13 A 70 mm thick layer of concrete shall be laid in place of asphalt concrete. 14 This shall be subsequently, broken out and replaced by asphalt, when asphalt plant is next

in operation15 Traffic management scheme shall be removed, after road crossing is cleared of all debris

and obstructions.16 Either side of road shall be provided with cable markers to indicate services

Major Equipment1 Excavator, Dumper trucks, Compactors. Jack Hammer, Compressor,

Attachment1 Sketch showing traffic management scheme

MS13Pre casting & installation of lighting poles foundations

IndexScope/Reference documents/Definitions/Responsibilities/Safety/Method/Equipment/Attachment

Scope1 This statement is aimed to propose procedures to be adopted to carry out pre casting,

transporting and installing on exact site locations, street lighting poles foundation bases 319 #

Reference documents1 Drawing # Not indicated2 Specification- Concrete


1 Safety precautions required, while working on excavations, mass concrete, forms, reinforcing bars, concrete pouring, concrete protection etc. etc all according to acceptable standards, shall be strictly adhered to on operations concerned

2 Adequate safety shall be observed during lifting and offloading precast concrete covers to relevant locations to avoid mishaps by observing regulatory crane fitness requirement and validity of permit to work.


and if so required, a banksman be engaged to direct movement5 Crane shall not be operated during inclement weather conditions with dust storms6 Adequate safety measures shall be adhered to during lifting and offloading precast

foundations to relevant locations avoiding any mishap by observing regulatory crane fitness requirement and validity of permit.

7 Crane and trailer operators shall abide by all traffic rules while carrying out operations and if so required, a banksman shall be engaged to direct movement



Chapter 7 External Works & Utilities8 Crane shall not be operated during inclement weather conditions with dust storms

Material1 Concrete of defined grade2 Reinforcing bars of defined specification3 Lifting Lugs well designed 4 Anchor Bolts to requirement5 100 mm dia. 350 internal radius PVC Cable Duct for electrical cabling6 Bitustick XL for belowground concrete protection7 Masterseal 300H for above ground concrete protection

Method (sketch # 8)Pre casting Area

1 Existing yard being used to precast manholes, catch basins etc. shall be employed for this purpose also

2 Following operations are involved to carry out production of lighting poles foundation bases

Pre casting operations in brief1 Fabricate and erect side forms 4 #s to specified dimensions2 Fabricate reinforcing bars according to specified details3 Provide non critical cathodic protection4 Provide PVC cable duct5 Provide bolt assembly to requirement and location6 Provide lifting lugs to carry a gravity load of at least 3 tonnes + handling stresses7 Pour concrete8 Cure concrete immediately after pouring

Post casting operations in brief1 Cure for specified period2 Excavate location to required formation level3 Blind area to be founded with concrete4 Waterproof blinding as specified5 Keep area ready in all respects well oriented & aligned to receive foundation directly to

be offloaded6 Apply waterproofing membrane around as specified7 Provide protection board as specified8 Backfill surrounding space to relevant grade level

Pre installation operations1 Typical size of foundation is 1000x1000mm in plan and 1100mm deep 2 According to drawing, 319 # are specified to be constructed (quantity 351 m3)3 On an average, 10 units shall be produced by pre casting everyday 4 Forms to exact size with preformed chamfers shall be prepared and erected 5 Steel reinforcing bars shall be cut, bent to required shape, placed and cage prepared

holding 75mm concrete spacers and positioned into forms.



Chapter 7 External Works & Utilities6 1 # 350 mm internal radius 100 mm dia. PVC cable duct, formed to suit dimensions shall

be anchored by binding wires to exact locations shown on drawing, keeping upper end flush with concrete top

7 Lifting lugs as shown on sketch shall be fixed in, at correct locations 8 Forms for block outs for lifting lugs shall be fixed in, at correct locations as shown,

without clashing with either with duct or with reinforcing bars, allowing a protrusion of hook

9 Bolt assembly shall be fixed in, at exact position according to design details10 Noncritical cathodic protection shall be arranged, using a metallic continuous binding

wire connecting all horizontal reinforcing bars, terminating into a boss, fixed at one location near top, at middle of side opposite duct carrying portion

11 All supports and dimensions shall be checked, corrected if required and plumb monitored12 Civil Contractor QC inspection shall be conducted at regular intervals throughout

operations13 Concrete shall be poured to all prepared units in 3 layers in vertical pouring sequence14 Appropriate vibrator shall be used for compaction of concrete 15 During concreting, care shall be taken to keep anchor bolts’ position undisturbed and

intermittent checks be continuously made to monitor spacing/centre between bolts16 Civil Contractor QC inspection shall be conducted, prior to concrete pour & ITP signed

off17 After concrete is poured in full & well compacted, surface shall be leveled, using a

wooden float, followed by light steel trowelCuring

1 Immediately, after concrete is finished, surface shall be covered with polythene sheet with edge lapped or tied down to exclude air circulation, without permitting membrane to be in touch with concrete surface inline/according to specifications

2 After concrete has stiffened, but no longer than 2 hours, polythene sheet shall be removed followed by immediate covering surface with saturated (soaked with mix quality water) hessian and recovered with polythene sheet to prevent evaporation from hessian.

3 Throughout curing period, hessian shall be maintained in a permanent wet condition, using mix quality water

4 Side forms shall be removed after specified period of 24 to 36 hours as agreed5 Vertical concrete surfaces shall be draped with saturated hessian immediately, after

striking forms and covered with polythene sheet held firmly in place along all edges & kept continuously wet for duration of curing

6 Curing shall be continued for specified period/inline conforming to defined period per specifications

7 Civil Contractor QC inspection shall be conducted from time to time throughout operations

Installation operations1 Relevant locations shall be made ready to receive precast units by completing excavation,

blinding, concrete protection and forming correct alignment 2 Civil Contractor QC inspection shall be conducted for location to receive & ITP signed

off



Chapter 7 External Works & Utilities3 Unit shall be lifted by a mobile crane, loaded gently onto a trailer and transported to

relevant area to offload onto prepared ‘location to receive’ 4 Unit shall be installed on marked location inline/according to correct orientation to street

lighting electrical layout drawing5 Civil Contractor QC inspection shall be conducted 6 Protruding lifting lug eyes shall be cut to 60 mm inside block out, void filled with

concrete by first scabbling internal surface, followed by cement slurry grouting and pouring concrete

7 Below ground surfaces of foundation shall be applied with concrete protective membrane inline/according to specifications

8 Civil Contractor QC inspection shall be conducted 9 Membrane protection board shall be provided covering surface to specified details. 10 Backfilling shall be carried out in layers inline/according to specification up to required

levels 11 Points to locate cathodic protection shall be provided with a marker to trace protection

boss. 12 Top surface of foundation shall be applied with aboveground concrete protection as

specified13 EPC Contractor surveillance/inspection/approval shall be according to relevant ITPs

Major Equipment1 Compressor, Mobile Crane, Trailer2 Concrete Pump, Transit mixer

Attachment1 Lifting arrangement sketch

MS14Electrical & instrumentation trenches


Scope 1 This statement is aimed to present procedures to be adopted to carry out construction of

Electrical and Instrumentation Trenches to typical details.

References1 Drawing Paving & Underground services2 Electrical and Instrumentation Trench and Duct Bank details

Specifications 1 Concrete




Chapter 7 External Works & Utilities1 Safety precautions required, while working on excavations, mass concrete, blinding,

forms, reinforcing bars, concrete pouring etc all according to acceptable standards, shall be strictly adhered to on operations concerned



and if so required, a banksman be engaged to direct movement5 Crane shall not be operated during inclement weather conditions with dust storms

Materials1 Mass Concrete for strip foundation beam, 2 Concrete blocks, 3 Precast trench covers, 4 Oil resistant joint sealant

MethodGeneralDummy/walled trench section (Detail 5 on reference drawing) Following operational sequences in brief are involved

1 Setting out to exact alignment route of trench to specified coordinates2 Barricading involved area to safety department direction and requirement3 Excavating trench to specified levels and sectional details4 Preparing formation to required levels and dimensions5 Formwork for sides of mass concrete strip beams6 Pouring mass concrete to strip beam forms7 Setting out alignment for trench block walls8 Block work 150mm thick in walls to specified levels upto pavement downstand beam

soffit level9 Preparation and concreting pavement portion monolithic with downstand beam extended

up to top of block wall 10 Backfilling trench with excavated earth to specifications11 Placing precast coloured concrete covers in 1m or 3m standard lengths on relevant

compacted area12 Sealing joint between pavement and trench cover

Details about above operations in general1 Surveyor shall set out alignment of trench concerned according to relevant details given

on paving and underground services location plans to reference coordinates2 Civil Contractor QC shall conduct inspection 3 Safety arrangement shall be discussed with safety department and implemented

accordingly, to control trench excavation to provide barricades, night lights, to divert traffic if so required and to adopt all other necessary measures.

4 Excavation shall be carried out by an excavator to lines and levels.5 Surveyor shall monitor all stages of excavation to achieve required profile



Chapter 7 External Works & Utilities6 Excavated material shall be transported immediately, by a dump truck to earth stockpiles

temporarily7 After excavation is over, formation levels shall be well dressed and compacted to

specification requirement8 Forms shall be fabricated for mass concrete section9 Fabricated forms of width 350mm and depth 100 mm shall be erected/fixed on prepared

compacted formation duly aligned and leveled10 Civil Contractor QC shall conduct inspection throughout stages of construction 11 Mass concrete shall be poured to marked levels and tamped by wooden float12 Forms shall be struck after specified period13 Curing of mass concrete shall be carried out inline/according to approved procedures and

for specified period14 Alignment of block walls 150 mm thick shall be set out, block work carried out in

courses in a straight line and plumb15 Whole number of courses shall be laid & fractional block course if so required/remained

to make up required wall height, shall be constructed as a part of pavement down beam concrete by extending bottom to top of block walls

16 Pavement/down beam monolithic pouring shall be carried out to specified details inline/according to procedures

17 Civil Contractor QC shall conduct inspection throughout stages of construction 18 Backfilling shall commence and trench filled according to specifications19 Precast covers of 1m or 3 m standard length shall be placed on filled trench internal

surface to specified levels20 Concrete shall be given required colour to specification requirement, Green for

instrument trenches21 Civil Contractor QC shall conduct inspection throughout stages of construction

Where dummy trench runs over duct bank (Ref drawing Detail 4, Sec A)1 All foregoing operations described in general shall be applicable herein as well with

following amendments/additions to certain activities2 Excavation shall be carried out to top of duct concrete only3 Walls shall be started from duct top level4 Additionally, where underground pipe runs X-ing Trench, specified pipe shall be laid

prior to block work is commenced or openings should be formed in walls (Pipe laying operation by others)

5 Flat width of crossing shall be in size equal to value given by equation “Duct Bank length + 300x2 “

Where dummy trench and direct buried trench run parallel (Ref Drg Detail 4, sec B) 1 All operations described in general shall be applicable herein as well with following

amendments/ additions to certain activities2 While constructing buried trench, profile of dummy trench shall dictate profile of buried

trench 3 Sloping profile to a grade 1 in 2 shall be formed as shown on drawing

Where cable trench crossing with closed drain pipe trench (Ref drg Detail 6 sec C)



Chapter 7 External Works & Utilities1 All operations described in general shall be applicable herein as well with following

amendments/ additions to certain activities2 Profile of cable duct trench shall dictate profile of direct buried trench3 Transition of formations between trenches and crossing shall be in grade 1 in 2 as shown

on drawing4 Length of duct bank shall be equal to value given by equation Width of closed drain

trench in mm + 2x1005 Crossing flat width shall be duct bank length + 2x3006 A gap of 100mm shall be kept between duct bank top and closed drain bottom surfaces7 Duct bank shall be constructed according to details 8 Cable tiles under closed drain trench shall be provided in direct buried trench only9 A joint shall be provided between pavement and closed drain trench wall

Where direct buried trench crossing under dummy trench (Ref Drg Detail) Sec G & H)1 All operations described in general shall be applicable herein as well with following

amendments/ additions to certain activities2 A level difference of 350mm shall be kept between elevations of crossing formation and

dummy trench3 Level transition shall be established by grading 1 in 24 Cables passing under dummy trench shall be protected by cable tiles (By others)5 Trench corner wall shall be constructed to details showing corner length on trench

internal face 8485mm

Where trench with dummy Trench crossing under direct buried cable trench (Ref Drg Detail 3 Sec E)

1 All operations described in general shall be applicable herein as well with following amendments/ additions to certain activities

2 Profile of cable duct trench shall dictate profile of direct buried trench3 Transition of formations between trenches and crossing shall be in grade 1 in 2 as shown

on drawing4 Length of duct bank shall be equal to value given by equation Width of direct buried

cable trench in mm + 2x1005 Crossing flat width shall be duct bank length + 2x3006 A gap of 100mm shall be kept between duct bank top and closed drain bottom surfaces7 Duct bank shall be constructed according to details 8 Cable tiles under closed drain trench shall be provided in direct buried trench only

Where direct buried trench crossing under direct buried cable trench (Ref Drg Detail 7 Section D)

1 All operations described in general shall be applicable herein as well with following amendments/ additions to certain activities

2 A level difference 700 mm shall be kept between direct buried trench and crossing formation level

3 Crossing formation width shall be equal to value from equation in mm (direct buried cable trench width + 400x2)



Chapter 7 External Works & Utilities4 Transition of formations between trenches and crossing shall be to grade 1 in 2 as shown

on drawing5 Cable tiles shall be provided in unpaved areas and at trench crossing (By others)

Electric Trench Layout at Pumps (Ref Drg Detail 13)1 All operations described in general shall be applicable herein as well with following

amendments/ additions to certain activities2 Pump base shall be constructed to details3 Trench walls shall be continued to shape as shown

Option1 If so required and felt convenient for certain uniform section reaches, precast concrete

units 100 mm thick may be utilized to substitute 150 mm thick walls directly resting on prepared formation

Equipment1 Excavator2 Dumper truck3 Compactor

Attachment1 None

MS15Pull pits


Scope 1 This statement is aimed to present proposed procedures to be adopted to carry out

construction of Pull Pits by pre casting method

References1 Specifications 2 Pull pit drawings3 Underground services & utilities drawings


1 Safety precautions required, while working on excavations, mass concrete, forms, reinforcing bars, concrete pouring etc all according to acceptable standards, shall be strictly adhered to on operations concerned



and if so required, a banksman be engaged to direct movement



Chapter 7 External Works & Utilities5 Crane shall not be operated during inclement weather conditions with dust storms

Materials1 Mass Concrete of specified grade, 2 Structural concrete of specified grade, 3 Concrete Blocks, 4 mm dia. GI Lifting Lugs (Galvanization on Exposed portion only), 5 Reinforcing bars all according to requirement

Method1 Following operations are involved

Operations in Pre casting YardPre casting Area

1 Existing yard being used for pre casting of manholes, catch basins and lighting poles foundations etc. shall also, be employed for this purpose

Formwork 1 Typical size of Pit type 1 cover is 1900x500mm in plan and 200mm deep 2 Typical size of Pit type 2 cover is 2900x500mm in plan and 200mm deep 3 According to schedule 71x 6 #s each=426 #s Type 1 and 81x 6 #s each=486 #s 4 Type 2 covers are quantified to be constructed 5 On an average, 20 units shall be produced by pre casting everyday 6 Wooden forms to exact dimensions with pre formed chamfers shall be prepared and

erected Reinforcing bars placement

1 Steel reinforcing bars shall be cut, bent to required shape, placed with 75mm concrete spacers and positioned into forms according to details shown for type P1 & P2

Lifting lugs fixing 1 Lifting lugs as shown on attached sketch shall be fixed into correct locations 2 All supports and dimensions shall be checked and corrected, if required3 Civil Contractor QC inspection shall be conducted before pouring concrete and

signatures appended to ITPs Pouring concrete & finishing

1 Concrete shall be poured into all approved preparatory works in 1 layer by directly delivering from concrete truck/transit mixer through chute

2 1 # ¾” needle vibrator shall be used to compact concrete and 1 # reserved standby3 After concrete is poured in full & well compacted, surface shall be leveled, using a

wooden float followed by light steel trowelCuring

1 Immediately, after concrete is finished, surface shall be covered with polythene sheet with edge lapped or tied down to exclude air circulation, without permitting membrane to be in touch with concrete surface inline according to specifications

2 After, concrete has stiffened, but no longer than 2 hours, polythene sheet shall be removed followed by immediate covering surface with saturated (soaked with mix quality water) hessian and recovered with polythene sheet to prevent evaporation from hessian.



Chapter 7 External Works & Utilities3 Throughout curing period, hessian shall be maintained in a permanent wet condition

using mix quality water 4 Side forms shall be removed, after specified period of 24 to 36 hours as agreed5 Vertical concrete surfaces shall be draped with saturated hessian immediately, after

striking forms and covered with polythene sheet, held firmly in place along all edges & kept continuously wet for duration of curing

6 Curing shall be continued for specified period of 14 days7 Civil Contractor QC inspection shall be conducted from time to time throughout

operationsLifting, loading & transportation

1 Covers shall be lifted by a mobile crane, loaded gently onto a trailer and transported to area concerned to offload on to prepared ‘location to receive’

On site operations post completion of work of laying Cable ducts1 Area around excavation coverage shall be barricaded to site requirement based on

direction of Construction SuperintendentSetting out

1 Setting out shall be carried out by surveyor to required coordinates2 Civil Contractor QC inspection shall be conducted throughout operation and ITP for

survey check signed off Excavation

1 Excavation shall be carried out (manually, if ducts are not encased in concrete) to specified formation levels i.e. 1300 mm (varying from area to area) from finished grade monitored by surveyor

2 Compaction and FDD tests if so required, shall be carried out inline accordinglyMass concrete base

1 Formwork for mass concrete 500mm wide and 150mm deep shall be prepared and erected to settings

2 Civil Contractor QC inspection shall be conducted from time to time throughout operations and concrete pour ITPs signed off

3 Concrete shall be poured to exact levels, finished properly and cured to specified procedures

4 Concrete protection shall be applied to mass concrete to details & specificationsBlock work in walls

1 200mm Block work shall be carried out as shown on drawings to required levels, so that cover top level is 100mm from finished grade/ground level.

2 In case, ducts are not laid in, opening shall be provided in wall3 Civil Contractor QC inspection shall be conducted from time to time throughout

operationsUn compacted sand fill

1 Un compacted sand shall be filled as shown on drawing & in accordance with specifications

Compacted backfill 1 Remaining portion shall be backfilled and compacted to specification requirement 2 Top surface shall be well prepared, compacted and leveled to receive precast covers

Placing precast covers



Chapter 7 External Works & Utilities1 Covers shall be offloaded by a crane from a trailer as transported from pre casting

yard to relevant locations ready with one layer 0.25mm thick polythene sheet with allowed laps 300mm, spread over

2 Covers shall be properly spaced and leveled to details shown on drawingSand fill

1 300mm deep sand backfill shall be carried out over laid ducts not encased in concreteBackfill

1 Compacted backfill shall be carried out above sand fill to specifications 2 Civil Contractor QC inspection shall be conducted from time to time throughout

operations with relevant ITPs signed offLugs Fill

1 Sand shall be filled in lifting lugs recessConcrete Protection

1 Exposed concrete surface is a part of pavement and therefore, no protection shall be applied

Equipment1 Transit mixer, Trailer, Vibrator, Crane,

Attachment1 Sketch -showing lifting lugs arrangement

MS16Protection to transformer foundation sides @ substations with

Aluminum bead termination for below ground and masterseal 300h for above ground on gravel fill area


Scope 1 This statement is aimed to propose procedures to be adopted to protect vertical surfaces

of transformer bases concrete using Aluminum Beads to clamp in waterproofing membrane termination around foundation sides and apply concrete protection coating on surfaces above ground

References1 Main Substation Drawing Transformer Foundations and relevant drawings for all other

substations2 Specifications


1 Only competent personnel shall be engaged to carry out operation2 Personnel shall use PPE, gloves, masks, eye protection etc. 3 Care shall be taken during use and storage to avoid contact with eyes, mouth, skin and

foodstuffs.



Chapter 7 External Works & Utilities4 To avoid skin contact, use of barrier cream to protect from adverse effect of material and

other chemicals application shall also, be made.5 Industrial cleaner shall be used followed by washing with soap and water.6 Containers shall be resealed after use. 7 Immediate medical attention shall be called for, in case of some adverse effect to

personnel handling product8 Damaged tins shall be disposed off according to state regulations.9 Material safety data shall also, be referred to, for disposal and all further information.

Materials1 Bitustick XL Polybit MAR 0032 Aluminum Bead lengths to Sectional dimensions 30 mm x 2 mm3 Fixing screws 3 mm dia.4 Joint filler Alpex Joint Fill BCR MAR 0085 Sealant- Polyurethane-Gun Grade Cold seal 200PF for horizontal usage on Aluminum

strip (Manufacturer BCR) (Emirates Specialties) or equivalent MAR 6 Masterseal 300H MBT MAR 0597 Masterseal 181S Primer system8 Masterseal 300H filler

Storage1 Manufacturer’s instructions shall be followed for this purpose.2 Material shall be stored under cover, out of direct sunlight and protected from impacts of

weather temperature extremes.

Method1 Waterproofing membrane shall be applied conforming to/according to specifications to

defined levels, keeping top edge 50 mm above gravel fill 2 Marking shall be made to exact line and level per drawing3 Required bead lengths to exact site dimensions shall be cut to suit a close fit between

bead ends4 Every bead shall be fixed with screws @ 400mm centres, drilled and tightened to

concrete penetrating membrane5 Screws shall be drilled and fixed, using an electrical operated equipment 6 After screws are drilled in with beads in proper alignment/location, compressed fibre

shall be installed as protection over Bitustick XL membrane as specified7 Civil Contractor QC inspection shall be conducted followed by EPC Contractor approval8 Vertical surface above bead as well as, a 50mm wide strip around top periphery of

foundation, shall be prepared for above ground concrete protection and Master seal 300 H be applied to manufacturer’s instructions

9 This application involves following sequences10 Cleaning and making up surface11 Priming surface12 Coating surface

Preparation1 All surfaces shall be free from oil, grease, friable matters and curing compound.



Chapter 7 External Works & Utilities2 Surfaces shall be cleaned from dust/sand using compressed air. 3 Arrises shall be rounded off and protrusions ground, so that resulting surfaces appear

smooth.4 Surfaces shall be brush primed with Masterkure 181S and subsequently, Masterseal 300H

mixed with Masterseal 300 H filler applied as a scrape coat over blow holes and depressions.

5 Primed surface shall be allowed to dry tack free for a minimum duration of 2 hours, before applying Masterseal 300H coating.

Application1 Areas to be coated shall be protected from direct sunlight, by shading in hot weather

conditions. 2 At time of coating application, ambient temperature shall be more than 5 degree Celsius

with humidity less than 90 % and no dusty weather 3 Masterseal 300 H shall be applied directly from containers using a brush or roller @ 0.8

litre per sqm surface coverage to achieve a continuous coating 4 Continuous coating shall be achieved in 1 or 2 coats of application5 Coating shall be protected from humidity for 24 hours/or, until it dries out using

polythene sheets keeping off coated surface area.6 No post application curing is required7 Civil Contractor QC inspection shall be conducted followed by EPC Contractor approval

Application of sealant shall be conducted after 24 hours 1 Material shall be applied using a sealant gun fitted with conical nozzles adjustable to suit

width2 Sealant shall be gunned into junction using an even trigger pressure3 Nozzle shall be cleaned occasionally to avoid contamination.4 A smaller timber spatula soaked in soap water shall be used to compact sealant into joint

for giving a smooth polish finish formation. 5 Mixing and application equipment shall be cleaned immediately after use6 Civil Contractor QC inspection shall be conducted followed by EPC Contractor/Engineer

approval

Equipment1 Electrical operated drill2 Sealant applying gun3 Brush and roller

Attachment1 None

MS17Grouting to steel tanks bearings on ring beams





Scope1 Statement is aimed to propose procedures to be adopted to grout space between top of

ring beams and steel tank base plate (acting as bearing) according to following drawings and specifications.

Reference Documents1 Drawings- Demineralised Water Tank2 Drawings- Spent Caustic Storage Tank3 Drawings- Fire Water Storage Tank4 Drawings-Fire Water Storage Tank5 Drawings-Caustic Storage Tank6 Drawings- Neutralisation Tank Water Tank7 Specifications


1 Only competent personnel shall be engaged to carry out operation2 Site Safety requirements relevant to application of Masterflow 928T MBT grouting

material according to manufacturer’s instruction and filling sand into minutely narrow spaces

3 Personnel shall use PPE, gloves, masks, eye protection etc. 4 Care shall be taken during use and storage to avoid contact with eyes, mouth, skin and

foodstuffs. 5 To avoid skin contact, use of barrier cream to protect from adverse effect of grouting

material shall also be made.6 Industrial cleaner shall be used followed by washing with soap and water, where grout

comes in contact with skin.7 Immediate medical attention shall be called for, in case of whatever, adverse effect

caused to personnel handling product8 Material safety data shall be referred to for disposal and other further information.

Method (sketch # 11 indicatively)1 Refer to sketch attached2 Space to be grouted shall be cleaned to remove all dirt and loose particles using

compressed air 3 Surrounding area shall be shaded to avoid effects of temperature extremes4 Grouting operation shall be carried out in pieces on tank circumference5 Surface shall be soaked in water for 24 hours prior to commence with operations6 Sand filling shall be carried out into spaces, leaving a clear portion 200 mm wide for

grouting purpose. 7 A backing rod 25 mm dia. shall be provided as shown on sketch8 Space to be filled in various locations shall be prepared by form strips of size equal to

thickness of grout circumferential and radial area. 9 Pouring end shall be kept open and after pouring is completed in prepared area, shall be

closed



Chapter 7 External Works & Utilities10 An electric drill fitted with a paddle mixer shall be used for grout mixing purpose. 11 Mixer shall be clean with allowing no standing water.12 Using water @ 3.5 to 4.5 litres per 25 kg bag of Master flow 928T according to

requirement for which, mixing shall be carried out as indicated in following explanation 13 90 % of measured quantity of water required to achieve desired consistency, according to

batch volume shall be added to mixer, followed by grout material Masterflow 928 T added gradually.

14 Remaining 10 % water quantity shall be poured during mixing, which has to be kept continued for at least 3 to 5 minutes, until an uniform lump free consistency is achieved.

15 Civil Contractor QC inspection shall be conducted according to ITP requirement16 Grout shall be poured continuously, using pour cone with a constant hydrostatic head of

at least 15 cm 17 Civil Contractor QC inspection shall be conducted according to ITP requirement18 After pouring grout Masterflow 928 in place, all exposed surfaces shall be covered with

clean and damp Hessian to keep applied material moist, until it is firm enough to accept a curing membrane

19 Grout thickness varies between 25 to 35 mm.

Major Equipment1 Paddle Mixer2 Grout Flow Cone

Attachment1 Sketch

MS18Soakaway chambers


Scope1 Statement is aimed to propose procedures to be adopted to carry out construction of

soakaway chambers

Reference documents1 Drawing # 2 Specification


1 In this case, excavation has to be carried out on Operating Authority area therefore all regulated precautions shall be strictly adhered to effect ‘full safety standard’.



Chapter 7 External Works & Utilities2 All safety precautions necessary during working on excavations, mass concrete, forms,

reinforcing bars, concrete pouring, etc. shall be applied to acceptable standards 3 Adequate safety measures shall be adhered to during lifting and offloading precast

perforated concrete manhole rings & covers to relevant locations, avoiding all mishaps by observing regulatory crane fitness requirement and validity of permit.


and if so required, a banksman shall be engaged to direct movement6 Crane shall not be operated during inclement weather conditions with dust storms

Material1 Concrete, Reinforcing bars/Lifting Lugs, Steps, Manhole covers

MethodPre casting Area

1 Existing yard being used to precast manholes, catch basins, lighting poles etc. shall be employed for this purpose also.

2 Following operations are involved to carry out production of soakaway chambers for circular arrangements but, casting may also, be conducted for square arrangements on similar patterns.

3 Factually, considering square section saves time of casting & allows ease of working & installation.

Description1 Typical size of precast rings are dia. 1800mm and 1200 mm & other details as shown on

sketch 2 Internal forms shall be erected to exact internal dia. and to specified height 3 Drain holes block out forms dia. 75 mm shall be fixed to internal shutter to suit circular

profile at ends, 8 #s in each row for 1200 mm dia. and 12 #s in each row in 1400 mm dia. staggered as shown on sketch

4 8T(not specified) steel reinforcing bars shall be cut, bent to circular shape, placed and cage prepared holding concrete spacers and positioned/placed into forms.

5 Block out form for inlet pipe shall be prepared and fixed to circular form, wherever required

6 Polystyrene sleeves shall be inserted for steps to be grouted, after forms are struck7 After all blackouts are fixed in, dimensions and plumb shall be checked8 Civil Contractor preliminary inspection shall be conducted9 External forms shall be erected to specified dia. and height & correctly supported. 10 All supports and dimensions shall be checked, corrected if required and plumb monitored11 Civil Contractor QC inspection shall be conducted & ITP for concrete pour signed off12 Concrete grade 30 shall be poured to prepared units in 3 layers in vertical sequence13 Needle vibrator shall be used for compaction of concrete 14 After concrete is poured in full & well compacted, surface shall be leveled using a

wooden float 15 Top circular strip shall be finished with a wooden float and covered with polythene sheet16 Civil Contractor QC inspection shall be conducted at regular intervals throughout

operations



Chapter 7 External Works & Utilities17 Immediately, after concrete is finished, surface shall be covered with polythene sheet

with edge either lapped or tied down to exclude air circulation without permitting membrane to be in touch with concrete surface according to specifications

18 After concrete has stiffened, but no longer than 2 hours, polythene sheet shall be removed followed by immediate covering surface with saturated (soaked with mix quality water) hessian and recovered with polythene sheet to prevent evaporation from hessian. Throughout curing period, hessian shall be maintained in a permanent wet condition using mix quality water

19 External and internal forms shall be removed after a specified period of 24 to 36 hours as agreed

20 Vertical concrete surfaces shall be draped with saturated hessian immediately, after striking forms and covered with polythene sheet held firmly in place along all edges & kept continuously wet for duration of curing

21 Curing shall be continued for specified period 22 Civil Contractor QC inspection shall be conducted from time to time throughout

operations23 Similarly RCC covers 250mm thick with circumferential web section 150x450mm shall

be precast to specified dia. 24 Relevant locations shall be made ready to receive precast rings by completing excavation,

mass concrete ring footing and forming correct alignment 25 Civil Contractor QC inspection shall be conducted for ‘location to receive' & ITP signed

off26 Rings shall be lifted by a mobile crane, loaded gently onto a trailer and transported to

relevant area to offload on to prepared ‘location to receive’ 27 Rings shall be installed on marked location according to correct orientation to relevant

layout drawing, keeping one ring above other, in such a way that steps to be grouted in, are formed in vertical alignment and perforations staggered, but centred vertically

28 Civil Contractor QC inspection shall be conducted 29 Space surrounded by mass concrete ring footing shall be backfilled with 40mm nominal

single size stones30 Another ring shall be placed over previous and jointed with cement mortar31 Excavation and laying of inlet pipe shall be carried out to details and block out filled with

concrete. Surrounding pipe and rings shall be backfilled with 40 mm nominal single size stones

32 Civil Contractor QC inspection shall be conducted 33 Precast covers shall be transported from pre casting yard, offloaded and properly located

over approved rings to correct alignment34 Manhole cover bedding/bearing shall be made of concrete by forming to given profile to

suit cover placing level35 After bearing concrete stiffens, cover frame shall be fixed and leveled using cement

mortar 1 : 336 Forms shall be erected for mass concrete surround with preformed chamfers and concrete

poured to a level 50 mm above grade level37 EPC Contractor surveillance/inspection/approval shall be according to approved ITPs




Major Equipment1 Compressor, Mobile Crane, Trailer, Transit mixer

Attachment1 Lifting arrangement sketch2 Drain Holes locations indicative only

MS19Cement based nonshrink grouting to foundation bases

using masterflow 928 tIndexScope/Reference documents/Definitions/Responsibilities/Safety/Method/Equipment/Attachment

Scope1 This statement is aimed to propose procedures to be adopted to grout base plates of

stationary equipment/vessels foundation bases using cement based non shrink grout material for a grouting thickness of 25 – 50 mm.

2 Grouting to be carried out between plates bottom & top of foundation bases

Reference Documents1 Specification


1 Area to be worked in shall be closed for general movement, except those involved with working there and be opened only, when work has properly been completed.

Method (sketch # 26 indicatively)1 Surface of foundation under base plate or equipment to be grouted shall be

chipped/scabbled & brushed to remove weak upper layer of concrete, damaged concrete and all oil soaked concrete areas without using mechanical bush hammer

2 Prior to grouting, loose concrete or dust shall be removed by compressed air.3 Concrete surface shall be soaked with clean water for 24 hours, prior to grouting to

minimize localized absorption as well as, to assist free flow of grout.4 Just prior to grouting, all standing water shall be removed, leaving only a damp film. 5 Base plates shall be clean and free of oil, grease, paint and correctly aligned according

to meeting details shown on drawings. 6 Leveling plates shall be set to proper elevation.7 Base plates and equipment bases shall be uniformly supported in order to eliminate sag

and distortion.8 Equipment bases shall be leveled using both anchor bolts and jackscrews.9 Stainless steel shims 50x50x10 mm thick shall be placed at correct locations, covered

with mortar, so as to allow at least 50 mm grout cover on shim sides.10 Forms as shown on attached sketch shall be erected on required locations with chamfers.11 An electric drill fitted with a paddle shall be used for grout mixing purpose.



Chapter 7 External Works & Utilities12 Water @ 3.5 to 4.5 litres per 25 kg bag of Master flow 928 shall be used according to

requirement.13 Mixer shall be cleaned left with no standing water.14 90 % of measured quantity of water required to achieve desired consistency, according to

batch volume, shall be added to mixer prior to adding Masterflow grout material, which material has to be added into mixer gradually and remaining 10 % required water quantity to be poured during mixing, which has to be kept working on for at least 3 to 5 minutes, until a uniform lump free grout consistency is achieved.

15 Grouting material shall be poured continuously using ‘grout pour cone’ with a constant hydrostatic head of at least 15 cm

16 Grouting shall extend to edge of concrete surface, where it is to be finished with a 25 mm chamfer

17 After pouring Masterflow 928 in place, all exposed grout shall be covered with clean dampen/saturated Hessian and kept moist, until applied grout gets firm enough to receive a curing membrane

18 Temperature less than 32 degree C shall be maintained for 3 post pour continuous days

Major Equipment1 Peddle Mixer2 Grout Flow Cone

Attachment1 Sketch2 Masterflow Catalogue3 Masterflow Method Statement

MS20Epoxy grouting to vibrating installation bases using masterflow

648 cp to general foundationsIndexScope/Reference documents/Definitions/Responsibilities/Safety/Method/Equipment/Attachment

Scope1 This statement is aimed to propose procedures to be adopted to grout base plates of

vibratory installations using epoxy grout material for varying grouting thickness for normal thickness range.

2 Grouting to be carried out between plates bottom & top of foundation bases

Reference Documents1 Specification


1 Area to be worked in shall be closed for general movement, except those involved with working there and be opened only, when work has properly been completed.



Chapter 7 External Works & UtilitiesMethod (sketch # 26/60 indicatively)

1 Thin section- A gap between a base plate and substrate below 25 mm2 Thick section- A gap between a base plate and substrate above 80mm 3 Normal thickness- In between thin and thick sections4 Refer to MBT clarification attached5 Following activities are involved for normal thickness

Surface preparation1 Metal parts that should not be bonded to grout like jack screws of reciprocating

machinery and part of foundation bolts shall be sealed with tape prior to grouting.2 Base plates and equipment bases shall be uniformly supported in order to eliminate sag,

distortion and leveled using both anchor bolts and jackscrews.3 Stainless steel shims 50x50x10 mm thick shall be placed in correct locations covered

with mortar, so as to allow at least 50 mm grout cover on shim sides.4 Full extent of foundation surface under base plate or equipment to be grouted shall be

chipped/scabbled & brushed clean to remove weak upper layer of concrete and also, chipped all oil soaked concrete areas prior to installation of base plate

5 Base plate surfaces in contact with epoxy grout shall be grit blasted, so as to expose white metal

6 All surfaces and bolt pockets to receive grout must be clean & free of rust, oil, dirt, paint and residual curing compound

7 All base plate holding down bolts etc. must be free of rust, oil, dirt or contaminants that could impair bond

Formwork 1 Unless otherwise shown on design drawing, entire area under base plate shall be grouted

for which, forms fixed around plate keeping a minimum 25 mm clearance from plate edges and at least, 50 mm from edge of pouring side, so that total grout able area is equal to underside of plate, plus clearance around plate.

2 Before formwork is fixed, it shall be ensured that foundation area to be grouted and bolts holes are clean

3 A liquid tight formwork as practicable, shall be fixed around base plate to prevent leakage of resin, keeping top of forms 25mm above underside of base plate

4 A chamfer 25mm x 25mm shall be provided on sides, so that top of chamfer and top of grout, are in one level in case, whole foundation area around plate is to be grouted

5 A 45 degree sloping surface above form on pouring side shall be constructed to create a pressure head to enable grout material flow to cover full width of pour

6 A coating of an approved release agent shall be applied to formwork 7 Civil Contractor QC inspection shall be conducted to ascertain adequacy respecting form

profile and general preparatory works

Grouting application1 All dirt and debris shall be removed from formwork using compressed air 2 Sufficient Grout material to completely fill prepared area in a continuous process shall be

made available 3 Mixing equipment shall be demonstrated to be in a suitable as well as, in good working

condition



Chapter 7 External Works & Utilities4 A standby equipment shall also, be made available 5 Concrete surfaces to be grouted shall be required to be completely dry before grouting

Mixing1 Grout Material Base and reactor components shall be poured into a suitable mixing vessel

and mixing carried out for 1 minute or until time successfully blended occurs2 All required quantity of aggregate shall be added to mixing vessel, which is to be kept

turning and mixing continued, until a uniform lump free grout material consistency is achieved.

3 Over mixing shall be avoided to prevent air entrainment

Placing1 All bolt pockets shall be filled with grout, prior to pouring rest of under plate space as a

separate operation to prevent voids formation2 Pouring of grout shall start from one end of base plate and continued, until material

reaches far side. 3 Mixed grout shall be steadily poured down provided formwork slope to avoid air

entrapment 4 Pouring shall be carried out only from one side of base plate to avoid creation of voids

and possible reduction of effective bearing area5 When grout reaches far side of formwork, which shall be ensured by poured material

rising above bottom of base plate, pouring location has to move along length of base plate, keeping process continued, until whole area is completed.

6 Civil Contractor QC inspection shall be conducted throughout above operations to ascertain proper implementation of procedures in line/according to manufacturer’s instructions

7 Shoulders- Exposed surfaces shall be brushed with Solvent # 2 just before or as grout gels

Curing1 No curing is required

Major Equipment1 Peddle Mixer/Mixing Vessel

Attachment1 Sketches2 Masterflow 648 CP datasheet3 MBT Method statement

MS21Kerbs & interlocking blocks paving around buildings





Scope1 This statement is aimed to propose procedures to be adopted to lay kerbstones and

concrete interlocking blocks on paving around buildings

Reference Documents1 Specification 2 MAR

Safety & Responsibilities 1 Refer to safety general description on page 1 & in addition2 Area to be worked in shall be closed for general movement, except those involved with

working there and be opened only, when work has properly been completed.

Material1 Kerb stones, Interlocking Paving blocks

Method (sketch # 56/57/57a/57b/57c indicatively)All loose soil shall be cleared, formation level made up and well compacted (Laying Kerbstones)

1 Setting out kerb excavation lines according to drawing2 Excavation up to formation level i.e. 325mm from kerb top level3 Formwork fixing and pouring grade 20 concrete 200mm wide and 100 mm thick4 Bedding in cement mortar 1 :4, 25mm thick for kerbstones5 Fixing kerb on mortar to true lines and levels with chamfer facing towards pavement

followed up by jointing with mortar6 Placing haunch back concrete grade 20, 150 mm high in triangular section7 Filling above haunch portion with soil8 Civil Contractor QC inspection shall be conducted for kerb laying approval and ITP

signed off

(Laying Paving Interlocking blocks)1 Thickness of interlocking blocks being 60mm for pedestrians use2 Thickness of sand bedding being 50mm3 Top level of sand in joint from kerb top level 50mm4 Sharp sand to be consumed, shall be piled up along area to be paved and evenly, spread

with blocks laid over snugly to agreed pattern and colour5 Plank runs shall be used to allow wheel barrows to move on them, to avoid level

disturbance6 Blocks shall be laid in full, but at edges of obstacles, such as inspection covers, where cut

blocks may be required, whole blocks shall be laid first, wherever possible and trimmable blocks exactly marked & cut using electric cutter to required size.

7 After sufficient blocks have been laid, sand bedding shall be compacted/carried out using a plate vibrator pressing blocks to required level in 2 passes covering entire area with each pass to make bedding even



Chapter 7 External Works & Utilities8 Sand shall be spread on surface of blocks with 2 more vibrator passes applied & brushed

under leading edge of vibrator to allow joints vibrated9 A Civil Contractor QC inspection shall be conducted to approve paving

Major Equipment1 Plate Compactor

Attachment1 Manufacturer’s Construction method

MS22Erection of steel structures (higher levels)



implemented for erection of steel structures.

Reference Documents1 Specification Grouting2 Specification Steel Structure Fabrication3 Specification Painting4 Specification Galvanizing5 Specification Structural Steel Erection6 ANSI A 10.13 Safety Requirements for Steel 7 Relevant IFC Drawings8 Method Statement Structural Steel

Definitions1 EF Erection Foreman

Responsibilities1 CM shall plan and resource steel structure erection activities to ensure that they are

implemented according to this procedure using consistent/correct equipment resources. 2 CS shall ensure that all safety requirements are implemented and explained to erection

workforce. 3 CS shall control day to day activities.4 EF shall control workforce ensuring full implementation of this method statement

including providing all safety measures.


1 Area to be worked in shall be closed for general movement, except those involved with working there and be opened only, when erection has properly been completed.

Main safety related items/activities to be implemented are:a Safe access to elevated levels



Chapter 7 External Works & Utilitiesb Man basketsc Full body harnessd All PP Equipmente Extra Harness Lanyardf Stay ropesg Life Line

MethodMaterial Receivables

1 All structural steel material to be used for permanent works shall be received on site and checked against relevant documents.

2 All members shall be checked for quantity and identification and transportation damage should it have been caused.

Concrete Foundations1 Surface of concrete foundation shall be prepared in accordance with specification to

receive grout.2 All concrete foundations on which, steel structures require to be erected shall be released

by QC department, upon completion of civil activity.3 No work respecting concrete foundations shall be carried out during erections activities

remain ongoing within concerned area, so as to avoid any possible damage to structural steel members.

Method Briefing1 Structures erected to date were low levels, varying from 6m to 16m and access was easy. 2 Now, structures to be erected would be at levels from 12m to 33m.3 All required structural steel materials shall be transported from main yard/store to site

location using flat bed trailer as usual.4 All members shall be sorted out for an easy accessibility & hoisting in certain sequence.5 All main columns/or grid frames shall be assembled on ground near adjacent to relevant

foundation. 6 Assembly shall then be installed on columns foundations using appropriate capacity

mobile crane. 7 Stay ropes shall be used to secure assemblies, until connecting horizontal

members/beams are installed. 8 All splice plates shall be installed and bolted down before horizontal members are

connected.9 Steel Catcher crew with necessary full body harness/lanyard shall be deployed/placed in

position on beams, using either a man lift or man basket.10 Full body harness shall secure steel catcher to steel members. 11 Steel Catcher shall move around on steel by ‘Slip & Slide’ method to get in position for

next member. 12 Life lines shall also, be pulled between columns so that steel catchers can walk on beams

below with their Safety Harnesses hooked onto life line. 13 Access ladders shall be installed as soon as, possible for safe access.14 Other option shall be open to install step ladders.



Chapter 7 External Works & Utilities15 All fasteners shall be installed and then line & levels checked. 16 When first level of steel with majority of horizontal members, are installed, line & levels

checked, grouting of column base plates shall then be effected per approved procedure.17 Mechanical QC inspection shall be conducted for approval

Platform\Handrails\Gratings1 After completion of main structural steel erection, platform\handrails shall be installed as

required per drawings.

Major Equipment1 Mobile cranes/Man lift/Man basket2 Guy ropes and tensioning equipment3 Flat bed trailers and forklifts\other mobile shifting equipment4 Air compressor5 Impact wrench6 Welding generators7 Grinding machines8 Drilling machines

MS23Concrete paving


Scope1 This statement is aimed to propose procedures to be adopted to construct concrete paving

on external areas around processing plant

Reference Documents1 Drawing Road & Paving Details Sheet 12 Specification


1 Area to be paved shall be closed for general movement, except those involved with working there and be opened only, when paving has properly been completed.

Material1 Fibre Concrete grade 30, Joint filler board, Crack Inducer, Welded Wire Fabric, Oil

resistant joint sealant

Method 1 All relevant underground/infrastructural services shall be laid & approved in all respects,

prior to commencement of pavement work2 Area to be paved shall be made ready by clearing all weak soil & by scarifying prepared

surface



Chapter 7 External Works & Utilities3 All portions of backfilled over services & other involved areas shall be compacted to

specification requirements following FDD/testing.4 Weed killer chemical shall be applied to soil to prevent organic growth5 On ‘compacted filled area’ to be paved, polythene sheet 0.25mm shall be placed with end

overlaps at least 150mm at all joints & intersections6 Approved sub base material 150mm thick shall be filled up to bottom of concrete slab

following profile given on drawing and compacted to 95 % dry proctor density7 Whole area shall be divided into parts to suit services & contraction joints formations as

shown on drawings8 End forms shall be fixed on sides allowing a provision to place 20 dia. MS dowel bars

650mm long @ 300mm centres, half applied with 2 coats bitumastic paint provided with 100mm long cardboard cap, containing compressible material, such as cotton waste at expansion joint to details shown on drawing, which indicates thickness of expansion joint to be 20mm, refer to detail.

9 At contraction joints, 25x25 mm plastic crack inducer shall be provided as shown on detail & joints cut for a depth of 20mm with a concrete cutting machine

10 Welded wire fabric mesh dia. 7mm 200# shall be placed in bay centrally located with concrete spacers below

11 Forms shall be set to correct levels, so that total thickness of concrete is achieved as specified on drawings followed by compressed air cleaning of all areas to be ready for pour

12 Civil Contractor QC inspection shall be conducted for pour approval13 Concrete shall be poured in one layer to correct levels & compacted using parker/

pocker/vibrator followed by giving brush finish. 14 Curing compound shall be spread on paved surface for immediate curing, covered with

polythene sheet and later within 2 hours damp hessian added by removing polythene sheet temporarily and recovered with polythene white sheets thereafter

15 Expansion joints between two adjacent slabs shall be filled with an elastic joint filler & sealed with a chemical resistant sealant complying with details shown on drawings Refer to details.

16 Details A shows 20mm x 25 mm joint seal and detail B shows 15mm x 20mm slightly rounded to prevent damage to edges

17 Civil Contractor QC inspection shall be conducted for approval of item.18 After works is over & curing days finished, area shall be open to pedestrians.

Major Equipment1 Concrete Pump, Transit Mixer, Parker/Dr Kewande Vibrator, Concrete cutting machine

MS24Concrete placement


Scope1 Purpose of this method statement, is to define procedure that shall be adopted for placing

structural concrete upon brown field project onto varying type of members, located all



Chapter 7 External Works & Utilitiesover proposed site including, heavy/light foundations, building components & all others internal as well as, external works.

Reference documents1 Project Specification 2 Specifications ACI 301 chapter 8


Method1 Structure that is scheduled to be concreted shall be inspected and approved as acceptable

for concrete pouring by both Civil Contractor and EPC Contractor/Engineer.2 Permission to place concrete shall be authorized by EPC Contractor3 Concrete Foreman shall ensure that all adequate equipment resources including standby,

(vibrating pokers, compressors, hoses, steel fixer, carpenter, stop ends, water etc), are available at location of concrete placement.

4 When major massive concrete pour is scheduled, a pouring plan shall be issued by project engineer or construction manager defining various sequences, which plan should be available with concrete foreman for implementation.

5 This plan shall help easy & successful pouring giving location of concrete pump, transit mixers arriving frequency, location of transit mixers during site sample testing, sequences of concrete either in layers in full or in stepping, so as to avoid formation of cold joints, duration of pours, strength respecting all classes of workers, curing arrangements, emergency solutions & other technicalities to be implemented such as, temperature controls & monitoring thermal gradients etc.

6 When site laboratory concrete technician has approved concrete delivery, concrete placement activity can commence.

7 Refer to Method statement, Testing of Fresh Concrete for further details.8 Concrete shall be discharged by one of two methods. 9 For pours greater than two cubic meters in volume, concrete shall be discharged through

a concrete pump or a mobile crane may be used. 10 For pours less than two cubic meters, concrete can be discharged direct from truck mixer

to location using a direct site fabricated chute, after concrete is delivered to site location chute from transit mixer chute or a mobile crane may be used.

11 Regardless of method of discharge, no concrete shall be dropped from a height greater than two meters or in a manner that causes segregation of aggregates.

12 Immediately, prior to placement activities commence, reinforcement within concrete pour shall be sprayed with clean water, which would prevent concrete from adverse impact of flash setting during high temperature environment.

13 Placement of fresh concrete within shutters shall be in a logical sequence, which sequence shall be agreed prior to commencing pour.

14 Concrete shall be placed at locations that do not exceed 1.5 meters from final location of concrete.

15 Maximum concrete layer thickness of 450 mm shall be observed, so that nozzle of pocker/vibrator interlocks lower poured layer, while vibrating current concrete layer.



Chapter 7 External Works & Utilities16 Fresh concrete shall be compacted with pokers of sufficient size and number.17 Oscillation of vibrator/pocker in no case, shall be less that 10000 per minute but, shall be

considered better, when it is more than 10000 oscillations. 18 Compaction of fresh concrete shall commence, when placement of concrete quantity is

adequate, so that uncontrolled segregation does not occur. 19 Concrete shall be placed in a sequence that ensures that cold joints are eliminated as

explained in foregoing. 20 Each subsequent layer of concrete shall be adequately, compacted into concrete layer

below as explained in foregoing.21 Where en cast plates, holding down bolts or some other critical embedded items are

included within pour, surveyor shall check locations and elevation of all such items, when concrete placement has not been completed.

22 All such embedment or inserts shall be inspected during pre pour approval inspections. 23 Records respecting pre & post pour of all such inserts shall be made for references to

verify locations confirmed within permissible limits of tolerance.24 Immediately, after laid concrete finishing has been completed, it shall be covered with

white polythene sheeting ensuring that edges are sealed to prevent circulation of air.25 Upon adequate setting of concrete, white polythene sheeting shall be removed

temporarily. 26 Hessian cloth, which has been soaked in water, shall be placed over set concrete. 27 White polythene sheeting shall be replaced and sealed at edges immediately. 28 Hessian cloth shall be kept moist for a period of 14 days or as specified within

specifications.29 Immediately, after laid concrete is ready to receive curing compound, it may also, be

sprayed if permissible by specifications. 30 Such provision shall prevent hair crack formation that is a result of shrinkage of concrete.31 In that case, immediate cover by white polythene sheet shall not be required but, later on

concrete would be covered as such, for continuous curing for defined number of days.32 When shuttering is removed from an element, exposed concrete surface shall be

inspected. 33 Where a defect is observed, defect shall be classified as either minor or major. 34 A minor defect is one, which does not impair strength of structure or is less than or

around 10mm by 10mm size only, which defect should be repaired using a patching mortar.

35 A major defect shall be brought to attention of QA department for investigation & resolution.

36 A major defect shall be other surface defect that is larger than 10mm by 10mm in size. 37 Method for repair of such defects shall be discussed and agreed with Engineer/EPC

Contractor.38 Repairs to concrete surfaces shall be cured according to meeting requirement for fresh

concrete.

Equipment1 Truck Mixer/Concrete Pump/Vibrating Pokers/Compressors

Attachment1 ITP # Concrete Placement



Chapter 7 External Works & UtilitiesMS25

Pre cast RCC covers for & instrumentation trenchesIndexScope/Reference documents/Definitions/Responsibilities/Safety/Method/Equipment/Attachment

Scope1 This statement is aimed to propose procedures to be adopted to carry out construction of

RCC covers for covering sand filled Instrumentation and electrical cable trenches.

Reference documents1 Drawing #s not included2 Specifications


1 Safety measures respecting handling these heavy covers shall be considered for hoisting to trailer, transporting & offloading to locations.

2 Since, covers are designed for varying dimensions, maximum weight in line to biggest dimensioned cover shall be considered to select type & capacity of mobile crane, with all precautions resorted to during crane operations, such as third party certification, location of stationing, using banksman, while crane swings & hoists.

Materials1 Coloured concrete Grade 302 Red colour concrete for covers to be used on Electric cable trenches3 Green colour concrete for covers to be used on Instrumentation cable trenches4 Red or Green oxides to be added to concrete @ 9 kg per cum5 Lifting Lugs, 16mm dia. with exposed portion galvanized, to be flush with concrete6 Prefabricated mesh 7mm dia. at 200/200 mm c/c

Method (sketch # 7/8/10 indicatively)1 Since various dimensions are involved for these typical precast concrete covers, details of

lifting lugs with exposed steel portion of lug to be galvanized, have been given on attachment.

2 Relevant details 5 L & 5 H on above drawing indicate transverse joints to be formed at a spacing of 3m in case of 150mm thick covers and 1 m in case of 50 mm (proposed to be substituted by 100 mm) covers

3 Pre casting shall be carried out in precast yard to approved procedures using coloured concrete

4 All other procedures pertaining to concreting & transporting members to site locations shall be similar to as being adopted

5 Prior to placing covers, filled compacted base in trench shall be prepared and polythene sheet spread to receive covers.



Chapter 7 External Works & Utilities6 Covers shall be offloaded to locations at specified spacing, leaving a gap of 25 mm

between ends to allow for oil resistant joint sealant7 Civil Contractor QC inspection shall be conducted to ascertain correct alignment and

level

Major Equipment1 Transit mixer2 Wheel barrows3 Mason’s tools in general4 Trailer5 Crane

Attachment1 Sketching showing lifting lugs

MS26Repair of single leaf swing gates


Scope1 This statement is aimed to propose procedures to be adopted to carry out repair to

emergency gates to be installed in substation fence for transformers. 2 A lock usable/function able from outside is to be added to gate.3 This function was not included with original design.

Reference documents1 Attached sketch

Safety & Responsibilities 1 Refer to safety general description on page 1 & in addition

Materials1 New post2 Self leveling grout to specification3 Epoxy paint system or galvafroid

Method 1 Vendor – Link Middle East Ltd or equivalent approved2 Existing gate post shall be cut using gas cutting equipment to a level as shown on sketch

and discarded3 A new post dia. 88.9mm including a locking lug shall be added with a sleeve, slot by

welding at vendor’s shop with 70 mm out to out PVC coated per specification. 4 A circumferential overlap shall be made in such a way that a minimum of 100mm

overlapping length lies below finished concrete level in addition to projection above 5 A portion of concrete necessary to allow working area (150 mm deep approximately) to

weld circumference on site shall be removed, prior to new post is erected for installation



Chapter 7 External Works & Utilities6 New assembled post shall be properly aligned to meet new requirement7 Welding shall be carried out to circumference 8 After welding galvafroid or epoxy paint system shall be applied according to meeting

manufacturer’s instructions9 Civil Contractor QC inspection shall be carried out for approval of welding and paint

system10 Surface of broken concrete shall be cleaned and approved11 Forms if necessary, shall be prepared and self leveling grout should then be applied to

manufacturer’s instructions and finished accordingly

Major Equipment1 Oxy Acetylene Gas cutting system2 Welding set

Attachment1 Sketch showing proposed arrangement

MS27Testing fresh concrete on site


Scope1 Purpose of this method statement, is to define procedure that shall be adopted for onsite

testing of fresh concrete delivered from Batch plant.

Reference documents1 Project Specification


MethodMaterial delivery

1 Site Laboratory shall be informed of concreting program by providing one copy of project specifications.

2 Each delivery of concrete to site, shall report to concrete Foreman/QC.3 Concrete Foreman shall assist laboratory technician in testing fresh concrete delivery.4 Delivery ticket shall first be checked for correct grade and type of concrete.5 Specific point to be examined on delivery docket to ensure that time of discharge from

batching plant & time of reaching/arriving truck to site does not exceed than maximum prescribed

6 Testing on site shall be conducted for following properties7 Concrete slump- should be within prescribed limits respecting crane or pump pouring8 Concrete temperature- should be within specified limits9 Air voids- should not exceed than defined



Chapter 7 External Works & UtilitiesPumping

1 Truck mixer shall discharge its delivery into concrete pump after all such site tests are completed.

2 Or Upon commencement of a pour, concrete pump operator shall flush its line with fresh concrete.

3 Initial discharge from concrete pump line shall be discarded.4 A sample of concrete circulated through concrete pump, shall be taken from end of

concrete pump line. Pumping operation shall then cease, until laboratory technician has completed his testing.

5 Temperature of concrete sample shall be determined according to ASTM C1064.6 A slump of concrete sample shall be conducted according to ASTM C143.7 These details shall be recorded upon test record format QC.8 Once these test results have been established as conforming to specification requirements,

concrete pumping operation can proceed9 Subsequent deliveries of fresh concrete shall follow a similar procedure. 10 Exemption being that initial discharge of subsequent truck mixers shall not be discarded.11 Laboratory technician shall take concrete samples from random truck mixers, for purpose

of concrete test cubes. 12 Frequency of these concrete test cubes shall be three cubes per 100 cubic meters of

delivered concrete. Additional concrete cubes shall be taken, as directed by laboratory manager for conducting further tests upon hardened cubes, as defined within specifications.

Equipment1 Truck Mixer/Concrete Pump/Slump Cone/Thermometer/Cube moulds

Attachment1 ITP #

MS28Replacement of misaligned anchor bolts in foundation 55-vv-906

using renderoc lax traIndexScope/Reference documents/Definitions/Responsibilities/Safety/Method/Equipment/Attachment

Scope1 This statement is aimed to propose procedures to be adopted to carry out replacement to

foundation damaged anchor bolts.

Reference Documents1 Method Statement # approved for concrete repairs Item F (Renderoc Lax Tra FOSROC)


Method



Chapter 7 External Works & Utilities1 2# Anchor bolts installed for this foundation were damaged post pouring

Following operations are involved to reinstate bolts into foundation1 Effected concrete portion shall be removed in a triangular form from foundation corners

in an approximate prismatic shape of base 250mmx200mm and height of prism 600mm approximately.

2 During breaking concrete, care shall be taken to not to damage reinforcing bars.3 Exposed reinforcing bars shall be properly cleaned using hard brush, so that no loose

particles remain intact to rebar surface4 Surface of broken concrete shall be cleared of all debris and new bolts installed in

correct locations5 Forms shall be erected to correct profile, aligned, properly leveled and plumbed. 6 Chamfer shall be aligned properly. 7 Form and concrete surface shall be properly sealed using silicon seal to avoid leakage

from poured renderroc laxtra material 8 Civil Contractor QC inspection shall be conducted to ascertain correct alignment of

anchor bolts and forms9 Then prepared surface shall be soaked in water for 24 hours prior to grouting 10 Material shall be mixed with specified quantity of clean water according to meeting

manufacturer’s instruction and poured in layers 200 mm thick11 Civil Contractor QC inspection shall be conducted throughout pouring operation 12 After approval of repair works and giving allowance of specified number of days, further

operations shall be carried out

Major Equipment1 Peddle Mixer

Attachment1 None

MS29Fixing sheeting panels wall & roof cladding


Scope1 Statement is aimed to propose procedures to be adopted to fix roof and wall metal panels

for various structures to be cladded


regulated precautions shall be strictly adhered to effect ‘full safety standard’.

Reference 1 Specification (Metals) for fasteners,2 Material3 MAR 4 Formawall for wall panels,



Chapter 7 External Works & Utilities5 Trisomet for Roof Panels, Profile EP3-Corrugated steel sheet (Single Skin)- by European

Profiles (BS/ HHR)6 Three types of panels shall be used as follows

1 Maintenance Building-Roof Panels- Trisomet, Wall Panels- Formawall Flat2 Car Parks- Corrugated Cladding3 Work shall be carried out by M/S ………

MethodPreparation

1 Prior to commencement of sheeting operations, structural items including door posts and parapet etc. shall be lined and leveled properly to requirements within acceptable tolerances

2 Wind brace clips shall be removed and building cleaned3 All necessary documentations i.e. Check List, RFI etc. shall be completed and submitted

prior to work commencement4 Civil Contractor QC inspection shall be conducted to ensure that structural elements are

aligned, leveled and fixed to specified requirement 5 Installation shall be carried out in accordance with provisions within specification

Fixing Roof Panels1 Valley gutters shall be fixed and aligned2 Internal ridge flashing shall be fixed in position3 Insulated Trisomet panels shall be fixed starting from valley, rising to ridge and all

fixings/accessories fastened on crown, meeting to specification requirement4 All end laps shall be cleaned of all dust, dirt etc. & sealed complying to manufacturer’s

instructions with mastic to prevent capillary humidity rise5 Procedure shall be repeated for parapet wall by fixing and aligning gutter 6 External ridge flashing shall be fixed7 Entire roof shall be brush cleaned and colour caps fixed8 Civil Contractor QC inspection shall be conducted throughout above operations to ITP

requirements

Fixing Formawall Flat PanelsFirst Tier

1 Drip flashing shall be fixed at base of wall to be used as a straight datum line2 First formawall vertical panel shall be fixed to true plumb and fastened by steel screws

throughout joints 3 Next panel fixed along side of first panel by providing a tight vertical joint & process

repeated, until end is reached4 Special flashing shall be fixed to entire length of first tier of vertical panels

Second Tier1 Second tier of blue panels shall be fixed in same manner as lower panel2 Procedure shall continue, until all sides are completed



Chapter 7 External Works & Utilities3 Special corner flashing shall be used/included/provided internally and externally to give

an aesthetic finish at corner joints4 Civil Contractor QC inspection shall be conducted throughout above operations to ITP

requirements

Car ParkCorrugated cladding

1 Single long panel shall be fixed & fastened to straight end of structure through crown with one and a half profile overlapped on sides and mastic inserted between sheets

2 Procedure shall be continued to curve, where sheets are to be racked and cut to provide roof curvature

3 Entire roof shall be brush cleaned and colour caps inserted4 Civil Contractor QC inspection shall be conducted throughout above operations5 Walls

Field Check for water leakage1 Upon completion of installation, walls shall be checked for Water Penetration in

accordance with AAMA standard 501.2-832 ‘Field check of Metal Curtain Walls for water leakage’ on designated area

Site Clearance1 All debris & excess material shall be removed making sure that no weep holes and

drainage channels are unobstructed and free of dust and sealantsEquipment

1 Man Lift2 Electric Drills

Attachment1 M/S subcontractor’s method statement ref…. 2 MAR approval reference….. 3 Note-QA Documentation Formats…../shall be submitted separately

MS30HDPE pipes butt fusion


Scope1 Statement is aimed to propose procedures to be adopted to carry out welding by fusion at

joints between HDPE pipes using COSMOPLAST/equivalent/advanced PE jointing technology


1 All safety means recommended by manufacturer COSMOPLAST/or equivalent (refer to page 14 & 35 on catalogue) as well as, required to be adopted by regulations shall be adhered to




Material 1 Pipes & fittings (COSMOPLAST or equivalent)

MethodElectrofusion-Precautions

1 A check shall be made about pipes to be joined are of same size to Standard Dimension Ratio (SDR) and consistent/competent material.

2 Only, compatible material shall be used3 Butt fusion machine shall be located/sited on a suitable clean, dry baseboard or ground

inside a shelter to minimize contamination and wind effect4 It shall be ensured that control box voltage is compatible with fitting5 Alignment/restraining clamps shall be used6 Pipe ends shall be cut square for electrofusion sockets7 Pipe or spigot surfaces shall be scraped fully, surfaces & fittings kept clean8 It shall be ensured that correct fusion & cooling times/hours are adhered to9 Joint shall be assembled & fused immediately, after scraping pipe10 Joint shall be completed in one go11 Fitting shall not be allowed to be taken out of protective bags12 Dirty fittings shall not be used13 Prepared pipe surfaces shall not be touched14 Assemblies shall not be allowed to get dampen before joining15 During welding/fusion cycle, weld shall not be touched16 Joint shall not be removed from clamp, unless full cooling time has elapsed17 Integral cutter shall not be removed from saddle, once main has been drilled

Pre jointing checks1 Only, regularly serviced equipment in good condition shall be used2 It shall be ensured that correct joining parameters for machine and pipe being welded are

known and clearly, understood 3 It shall be ensured that generator has sufficient/adequate quantity of fuel for duration of

programmed work. 4 Heater plate should be cleaned or washed, using only clean and cold water and dried out

with a clean lint free cloth or paper towel5 A check shall be made to ascertain that trimmer is clean with undamaged blades in good

condition6 It shall be ensured that clamp liners and securing screws of correct size are available for

size of pipe to be joined. 7 Lines must be clean and should sit fully in pipe clamps to ensure correct alignment.8 A check shall be made to ensure that heater plate is at correct temperature 9 Correct parameters shall be selected for pipes to be joined

Making Joint1 In an emergency, ‘red stop reset button’ when put off, shall stop all automatic cycles and

set machine safe and return to start of cycle



Chapter 7 External Works & Utilities2 Dummy weld shall be made to remove all fine particles from heater plate, before every

welding session, after changing from one pipe size to another pipe size & also, if heater has been allowed to cool

Connection & Pipe selection1 Heater, chassis and trimmer cables shall be connected to computer2 After ensuring that hydraulic connections are clean, connection shall be made to

controller3 Generator shall be started & computer connected to generator4 Pipe to be connected shall be selected5 Data shall be confirmed

Pipe Preparation1 Pipe Preparation shall be carried out according to description given on page on

manufacturer’s catalogue

Making weld1 Making weld shall be carried out according to description on page on manufacturer’s

catalogue2 Quality checks shall be conducted according to description on page 3 All Do’s described on page 13 shall be followed and don’ts on page 14 avoided4 Joint assembly preparation shall be carried out to indicative description on page 5 Pressure testing of joint shall be conducted complying to indicative description on page

Quality CheckQuality shall be checked to indicative description on relevant page of datasheet/catalogue Check (Butt Fusion)

1 That fusion indicators have risen, while fitted2 That no melted material or wire has exuded from fitting3 That pipe has not moved from fitting4 That area around joint is clean5 Evidence of scraping shall be checked6 That saddles are square on pipe7 That print out is taken from control box and result checked

In case, weld fails, following checks shall be required,1 For sockets, joint shall be cutout and use another fitting2 For saddles, main shall not be taped, but a repeat weld carried out, using a new fitting at

least 200mm from failed joint3 Civil Contractor QC inspection shall be conducted throughout above operations as

required according to ITP and procedures

Major Equipment1 Generator, Electrofusion control box, Restraining & alignment equipment, Welding

tent/shelter & ground sheet, Scraping equipment, Pipe cutter, Indelible Marker pen



Chapter 7 External Works & UtilitiesAttachment

1 Cosmoplast Method StatementMS31

Roof & side cladding plant areaIndexScope/Reference documents/Definitions/Responsibilities/Safety/Method/Equipment/Attachment


implemented for installation of Roof and Side cladding on mentioned structures.

Reference Documents1 CENTRIA Drawings – CR-56 Roofing/Single Skin

Definitions1 EF Erection Foreman.

Safety & Responsibilities 1 Refer to safety general description on page 1 & in addition2 EF shall control workforce ensuring full implementation of this method statement

including all safety measures.

MethodMaterials receivables

1 All cladding material to be used for permanent works shall be received on site on to appropriate lay down area.

2 Items shall be inspected against necessary shipping documents.3 All cladding shall be checked for quantity and identification.4 Materials shall be properly stored and protected.

Fasteners (bolts, nuts & washers)1 Upon receipt on site required fasteners, a minimum of one sample shall be selected and

tested by an independent laboratory to confirm specification conformance.

Installation of cladding: Roof and Side claddingCladding sheets shall be installed as follows

1 One by one from scaffolds and working platforms.2 Install in accordance with approved erection drawings and instructions.3 All panels shall be erected left to right, unless otherwise noted.4 Panel cutoffs shall be made, after all material is erected.5 All cutting and notching of panels around windows, doors, louvers, etc. shall be done

on site, using right/suitable compatible tools as listed. 6 All edge cuts shall be coated with clear spar varnish.7 All bevel and notch cutting of panels shall be made on site.8 All panels notched around beams and channel shall be flashed properly.

(for further details see enclosed MOS from Centria manufacturer)




Construction sequence of side & roof sheeting1 Monitor on roof shall be sheeted first.2 East and West sides shall follow, then North and South sides, including flashing in fills.3 Roof and Flashings (corner) shall be last items to be installed.

Erection of sheeting (side)1 Erection of side sheeting shall be lifted from ground between floor beams and side girts,

since sheets are too long to lower from roof because of being in one piece.2 North side scaffolding shall be installed from ground floor and regarding laydown area,

EPC Contractor Construction team shall provide.

Equipment1 Drilling Machines 2 #s2 Screw Guns 2 #s3 Screw Gun Sockets 2 #s4 Rivet Gun 1 #s5 Nibbler 1 #s6 Double Cut Shear 1 #s7 Jigsaw 1 #s 8 Vice Grips 2 #s9 Sheet metal Snips 1 #s10 Extension Cords 2 x 50m 3 #s 11 Drill bits 10 #s

Attachment1 Scaffolding erection of side sheet

MS32Ethylene export foundations along fence below

‘fertil overhead conveyor for pipe rack leading to seaIndexScope/Reference documents/Definitions/Responsibilities/Safety/Method/Equipment/Attachment

Scope1 Objective of this statement is to outline procedures to be adopted to carry out

construction of proposed pipe rack foundations along fence from near PS 2061below ‘Fertil overhead conveyor’ & up to sea for Ethylene export facility

Reference1 Pipe Supports GA & RC Details Foundations


regulated precautions shall be strictly adhered to effect ‘full safety standard’.


Miscellaneous Tools



Method (sketch # 20 indicatively)1 Required permit to work shall be obtained from Plant Refinery Division.2 Record drawings regarding existing services shall be obtained.

Procedures1 These foundations shall be located 3m off existing Sulphur Plant fence towards conveyor2 Layout shall be set out by surveyor to design requirement3 Civil Contractor QC shall inspect layout & approve4 Hand excavation shall be carried out to expose live cables & other services by employing

seaming involved area with detectors to discover existence of cables 5 Remaining portion of trench shall also, be excavated manually to defined levels6 All post excavation operations shall be carried out according to approved procedures,

such as preparation of formation levels, blinding concrete, formwork, placing steel reinforcement, anchor bolts fixing, noncritical cathodic protection, concrete pouring, concrete curing, application of concrete protection, backfilling etc.

7 Civil Contractor QC inspections shall be conducted to checklists & ITP requirement from time to time

Major Equipment1 Compactors, Concrete pump, Compressor, Shovel etc

Attachment1 Drawing Copies

MS33Reinstatement to

‘damage caused Flare pipe rack Column member 01537’ @ grid 19aIndexScope/Reference documents/Definitions/Responsibilities/Safety/Method/Equipment/Attachment

Scope1 Objective of this statement is to outline procedures to be adopted to carry out

reinstatement to Flare Pipe Rack structural steel column located at indicated grid, which was damaged during construction operations by Civil Contractor effecting adversely, on structural adequacy of member, necessitating replacement & until that stability is achieved, formation of a temporary arrangement to bear existing erected structures/all dead & live load elements.

2 One STQ was raised by Civil Contractor for approval pertaining to proposed and carried out operations, but EPC Contractor responded to require a proper method statement in this regard.

References: 1 STQ 2 Specifications- for Steel structure fabrication/for Painting/for Galvanizing/Project

Preservation & Export Packing



Chapter 7 External Works & UtilitiesSafety & Responsibilities

1 Refer to safety general description on page 1 & in addition, whatever included for safety within method given below

MethodReinstatement involves following main operations

1 Formation of a temporary arrangement2 Erection of new design structural steel column at grid 19A

Temporary supporting arrangement to be provided to achieve & maintain structural stability pertaining to permanent works as effected due to column at grid 19A getting damaged referred to details on attached sketch, has been carried out to allow dismantling & re erection of concerned members involving following sub operations.

1 Addition of 2 #s columns 203x46mm size located at mid spans of both adjacent bays2 Effected anchorage of these columns through top of member by Turfer to existing

column base3 Support of top bore pipe effected by wire sling & chain block around pipe & beam by 2

#s chain blocks to support top beams around pipes4 Chain blocks used to support 2#s bottom beams5 Arrangement applies to both additional temporary columns6 System is stable for purpose of transferring induced stresses, until new design column is

erected to its original location7 Civil Contractor QC inspection shall be conducted to ascertain adequacy/soundness

respecting erected temporary structure8 Safety officer shall ascertain sustenance of arrangements pertinent to possible hazards

Erection of new column Procedures

1 Civil Contractor QC inspections shall be conducted to checklists & ITP requirement prior to commencing this operation

2 Column structural material shall be received from Fabricator workshop & transported for galvanization

3 Identification of delivered members shall be checked4 All materials received shall be properly stored and protected

Foundation1 Pier surface shall be properly scabbled, brushed & made suitable for further operations. 2 All damaged concrete shall be repaired to agreed procedures3 Civil Contractor QC inspection shall be conducted to make sure that prepared surface is

satisfactory for grouting and erection operations4 Fasteners-One sample each of bolt, nut & washer, shall be selected & tested by an

independent laboratory5 Stainless Steel shim plates (25 mm thick) shall be placed at column centre, secured and

leveled, followed by application of an approved grout material around shims with a minimum 50mm cover to plates to be embedded in permanently

6 Civil Contractor QC inspection shall be conducted to make sure that plates are properly located & leveled & as built survey report recorded



Chapter 7 External Works & Utilities7 Columns shall be installed on pier using a crane, leveled, plumbed & anchored by stay

ropes to provide stability to member, until horizontal members are connected8 Foundation bolts shall be hands tightened only9 Necessary tightening or torque shall be effected post grouting10 Existing horizontal members & bracing interconnecting these grid frames shall be joined11 Vertical & horizontal members assembly shall be carried out in sections12 On completion of each beam with all fastenings in place, tightening shall be carried out

following final level & alignment checked13 Civil Contractor QC inspection shall be conducted to comply with ITPs & check list

requirements14 After assembly has been released, grouting shall be carried out complying with approved

procedures15 When new structure is reinstated to full requirement/adequacy, temporary structural

arrangement provided to withstand forces from unstable structure, shall be removed without effecting permanent members

Major Equipment1 Crane 30T/50T/ Flat bed trailer for fabricated material transport/ Shovel for minor steel

members movement/Guide ropes & tensioning equipment/men baskets to requirement/Scaffolding movable & stationary/Air compressor/Impact wrench/Welding generator to requirement/Portable grinding machines/Portable drilling machines

Manpower1 Foreman, steel erectors, Crane operator, Riggers, Unskilled workers

Attachment1 STQ copy

MS34Roads bituminous concrete surfacing


Scope1 Objective of this statement is to outline procedures to be adopted to carry out Roads

Bituminous Surfacing by Asphalt Concreting throughout site planned permanent roads quantifying to,

2 Binder Course Approximate area 130,000 m^23 Wearing Course Approximate area 70,000 m^2 4 Including areas completed & excluding access road to Highway

References:1 Roads & Paving Details2 Specification 3 All Paving & Underground Services IFC drawings 4 QCF Rev D & ITP



Chapter 7 External Works & UtilitiesSafety & Responsibilities Refer to safety general description on page 1 & in addition

1 In this case, excavation has to be carried out on Operating Authority area therefore all regulated precautions shall be strictly adhered to effect ‘full safety standard’.

Material1 Premixed bituminous binder course and wearing course materials shall be supplied from

Civil Contractor central batching, mixing & heating plant located on Highway

Method (sketch # 20 indicatively)1 According to project drawing, asphalt concrete shall be laid in an overall width of 13m &

9m for plant & access roads respectively2 13m width comprises of 9m central wearing course/carriage way & 2 m wide shoulder on

each side3 9m width comprises of 6m central carriage way & 1.5 m wide shoulder on each side4 Wearing course thickness being 40mm & that of dense bitumen binder course 60mm5 Paving works shall be carried out in 2 stages

Stage 11 Laying & compacting bottom bituminous binder course 2 Everyday production 7000 m^2 of laying & rolling during daytime

Stage 21 Laying & compacting top wearing carriageway2 This layer shall be carried out during defined/scheduled time 3 Proposed work shall be divided into areas & carried out in sequence in both stages,

depending on priority & production coordination as necessary, to be kept in line to proper execution of other dependent items

Surface preparation 1 Prior to an application of dense bitumen binder course, already laid & compacted

aggregate base course shall be prepared suitable for this purpose2 Base course shall be corrected of all deviation more than 13mm from designed profile at

all points & not more than 9mm in 3m on longitudinal grade at all/any location by either adding to or removing from surface, deficient or redundant material respectively to bring surface to design shape, watered & compacted in accordance to specification

Main Operations Following main operations are involved

1 Re preparation of aggregate base course surface with water & compaction by pneumatic roller (it is presumed that base course was carried out long back as well as, used during project prosecution activities)

2 Application of Priming coat & drying out3 Application of 60mm thick dense binder course4 Power broom completed dense binder course5 Application of Tack coat & drying out



Chapter 7 External Works & Utilities6 Application of 40mm thick bitumen concrete wearing course

Mixing1 All materials shall be mixed at Civil Contractor calibrated & approved Plant/Asphalt

plant2 All trucks and other equipment as included, shall be readily available for inspection

Transportation1 Material shall be transported from plant to planned location in good condition by trucks

cleaned of all foreign material & covered with tarpaulin to prevent dust invasion in inclement/adverse weather conditions

2 It shall be ensured by obtaining observations using thermometer that material, when laid is within 130 to 165degree C

ApplicationCoverage

1 Primer coat @ 0.8 to 1.4 litre/m^22 Tack coat @ 0.4 to 0.7 litre/m^2

Primer1 Civil Contractor QC inspections shall be conducted to ascertain correct profile of

aggregate base course & corrections applied, if so required2 All surfaces planned to be primed shall be barricaded & cleaned of all dirt & all

objectionable material3 Bituminous material shall be applied evenly, on dry surface, by means of a pressure

distributor spray tanker within a temperature 30 degree to 70 degree C

SurfacingBinder Course

1 Civil Contractor QC inspection shall be conducted prior to commencement of binder course laying to make sure that surface is satisfactorily clean, well dried, even to specified priming conditions & ready/suitable to receive binder course

2 Material upon arrival at location shall be spread & struck off to prepared profile by means of self powered spreading & finishing equipment attached with a strike off assembly distributing mixture to a 3 m wide strip

RollingSteel Roller’s # of passes 6 to 8 depending on surface condition

1 Steel rollers 10 T 18T capacity equipped with adjustable wheel scrapes, water tanks & sprinkling apparatus to keep wheel sufficiently wet to prevent bituminous mixture from sticking to steel surface, shall be employed to roll profiled material immediately, after material is laid to acceptable profile, so as to prevent formation of undue displacement or hair cracking

2 Roller wheels shall be kept properly moistened, without excess water or oil



Chapter 7 External Works & Utilities3 Rolling shall be commenced from side and proceed towards centre, each trip overlapping

previous by at least 300 mm wide, keeping alternate trip not more than 5 km/h & it should continue, until surface is achieved impression free

4 Mechanical compactors shall be engaged to work on roller inaccessible area layers5 Pneumatic tyred rollers shall be engaged only, after compaction by wheel roller is over6 It is significant to make sure that asphalt temperature does not fall below 80 degree C

prior to full compaction is achieved7 Roller shall not pass over edges of freshly laid material generally, except when edge is

located at a discontinuation for that day8 Civil Contractor QC inspection shall be conducted throughout above operations to make

sure that material is compacted to standards and temperature remains within limits mentioned as well as, levels are maintained within specification tolerances particularly, over areas involving shoulders

9 At commencement of work on area involving compacted & chilled edge, a bevel shall be cut out, cleaned & tack coat applied to receive adjoining material

10 No traffic shall be permitted, until 12 hours lapse period post rolling completion

Wearing Course1 Planned surface shall be cleared of all dust & dirt using power broom or blowing2 Tack coat shall be applied to specification requirements3 Immediately, upon arrival, material shall be spread & rolled similarly, as described in

foregoing4 Civil Contractor QC inspection shall be conducted throughout above operations to make

sure that material is compacted to standards and temperature remains within limits mentioned as well as, levels are maintained within specification tolerances

Major Equipment1 Required for binder course2 Central Mixing Asphalt plant 1#3 Trucks 5 #s 38 Tonnes capacity each4 Paver 3 #s, 1 # with 6m wide blade & 2 #s with 4m wide blade5 Steel wheel Tandem Rollers 2 #s, 1 # 10 Tonnes capacity, 1# 15/18 Tonnes capacity6 Pneumatic Tired Rollers(tyre inflatable at 0.62 Mpa ) 4 #s, 2 #s 38 T & 2 #s 20 T7 Air Compressor 1 #8 Asphalt Cutting Machine 1#9 Plate Compactor 1 #10 Jumping Jack Compactor 1 #11 Spray Tanker 1 #12 Additionally required for Wearing Course shall be procured later, when that course is

applied13 Power Broom14 Vacuum Cleaner

Attachment1 None

MS35



Chapter 7 External Works & UtilitiesReinforcement ‘receive & fabrication’


Scope1 Purpose of this method statement, is to define procedure that shall be adopted for material

receipt, fabrication and storage of reinforcement.

Reference documents1 Specification- Concrete Construction, Formwork and Coatings


Method1 Store man shall ensure regarding, whatever, reinforcement materials received upon site,

is in accordance with specification requirements, purchase order and quality documentation requirements.

2 Store man shall inform QA department & site engineer, when a delivery of reinforcement is made.

3 Store man, site engineer and QC inspector shall review reinforcement delivery and complete Material receiving report QCF.

4 Quality documentation shall be kept/record by QC department.5 When incoming material inspection is completed and acceptable, reinforcement material

shall be stored in reinforcement fabrication yard in appropriate storage facilities.6 Fabricated reinforcement bars shall not be stored on ground but, a suitable base be

prepared, while store bars would not be exposed to weather by using plastic or polythene sheet cover.

7 When reinforcement is to be ‘cut and bent’ yard Foreman shall be issued with a current rebar schedule. Yard Foreman shall review schedule and allocate fabrication process to relevant operator.

8 Material required shall be sourced from yard storage facilities.9 Correct bar diameter shall be cropped into specified length, as given on bar schedule. 10 Cropper operator shall crop required bars of each diameter.11 Upon bending of first of each bar type, fabricated bar shall be checked by yard Foreman

for correctness. 12 This fabricated bar, if correct shall be utilized as a ‘check bar’ for all concurrent bars of

that type. 13 Bending operator shall fabricate required number of bars of each shape code, checking

against ‘check bars’ as each bar is completed. 14 Error in bending of bars shall be corrected prior to placement in storage15 Correct bent bars shall be stored in bundles.16 Bundles shall be tagged with a suitable label that indicates relevant bar reference

#/schedule # from which, these bars have been fabricated.



Chapter 7 External Works & Utilities17 Completed bundles shall be stored within reinforcement yard, until such time required on

site. 18 Storage shall be done in accordance with procedure for stores control.

Equipment1 Bar cropping machines/Bar bending machines/Fork lift truck

Attachment1 ITP # 2 QCF, Material Receiving Report.3 QCF, Reinforcement Fabrication Check List.

MS36Reinforcement placement


Scope1 Purpose of this method statement, is to define procedure that shall be adopted for

placement of reinforcement.



Method1 Relevant reinforcement bars, spacer blocks, chairs, stirrups and tie wire, shall be

collected from stores and made available at work site. 2 Material shall be stored at worksite in accordance with storage procedure.3 Current revision of reinforcement drawing that applies to structure being constructed,

shall be checked by Project Site Engineer whether or not updated version either on drawings register or @ DCC.

4 Steel fixers shall place to tie reinforcement bars and accessories, in accordance with current reinforcement drawing as update verified by Project Site Engineer.

5 Particular attention to following items shall be monitored by charge hand steel fixer and Foreman:

6 Lap length of bars in reference to either notes or project specification.7 Tie wire protrusions into cover areas.8 Concrete cover/spacer to formwork and outside faces, about thickness of varying

locations.9 Placement of adequate support chairs and stirrups for upper reinforcing bars & beams.10 Spacing of bars for all reinforcing bars to be in line with design requirements.11 Charge hand steel fixer shall ensure/check fabricated reinforcement, when all placing of

reinforcement bars are complete.



Chapter 7 External Works & Utilities12 Result of this inspection shall be recorded upon form QCF Pre concrete inspection by

Site Engineer.13 Foreman steel fixer shall ensure that reinforcement has been checked by Site Engineer

prior to informing QC inspector.14 Should some inserts, conduits, pipes, bolts etc. require fixing within structure, steel fixer

shall assist with placement of these items. 15 Where a reinforcement bar clashes with such items, steel fixer shall move relevant bar as

instructed by site engineer/foreman/supervisor. 16 An additional bar may be required to offset this moved bar to be decided by QC/Site

Engineer. 17 Should some doubt arises about moving bars, charge hand shall inform Foreman to

resolve issue with engineers.18 Requirement for installing cathodic protection system to reinforcement bars shall be

conducted. 19 Foreman shall inform engineer, when these activities are complete.20 QC inspector shall inspect structure for compliance with reinforcement drawings and

layout drawings.21 QC inspector shall only allow next activity to commence, when all issues are acceptable. 22 QC inspector shall endorse form QCF, when acceptable.

Equipment1 Hand tools

Attachment1 Pre Concrete Inspection form

MS37Formwork erection


Scope1 Purpose of this method statement, is to define procedure that shall be adopted for erection

of formwork.



Method (sketch # 41-55 indicatively)Refer to sketches

1 Formwork Foreman shall review drawing of structure to be formed & shall decide along with project site engineer, most suitable method of formwork erection.

2 Where prefabricated formwork can be assembled in formwork workshop, shall be conducted.

3 Surveyor shall establish lines and levels for erection of formwork.



Chapter 7 External Works & Utilities4 These lines and levels shall be explained to Foreman and supervisor in charge of

formwork activity.5 Foreman shall check that preceding activities have been approved, so that formwork

activity may commence. 6 Sections of formwork required for relevant structure, shall be transported/shifted to

worksite.7 Tradesmen shall ensure that formwork faces are clean & in good condition for type of

finish required, applied with shutter form oil.8 Tradesmen shall assemble and fix formwork in accordance with current drawing.9 Charge hand carpenter shall monitor particular issues such as:10 Sealing of joints between formwork.11 Plumb of formwork.12 Adequate bracing and supports.13 Provision, where applicable for box outs and inserts.14 Provision, where applicable of chamfer and channels.15 Supervisor and surveyor shall check lines and levels of formwork, when all bracing and

strutting completed. 16 Where required, formwork shall be adjusted to conform to set out lines and levels.17 Supervisor shall ensure that damaged face of formwork is repaired.18 Foreman shall review formwork, when completed.19 Where anchor bolts or embedded plates are to be inserted in structure, supervisor shall

ensure that these arrangements are placed in formwork in line to as indicated on shop drawings, securely braced.

20 All embedment and bolt groupings shall be checked for location and level prior to placement of concrete (as pre pour check) as well as, after concrete is placed (as post pour check).

21 When formwork activity is complete, supervisor shall inspect formwork and associated works, recording observations on form QCF, formwork check list and QCF, embedment check list.

22 QC inspector shall confirm acceptance of this preparatory activity after review of worked items.

23 Where large formwork elements are encountered, QC inspector shall review formwork bracing’s and supports with project site engineer, point out missing, instruct adjustments, instruct modifications etc.

Equipment1 Hand tools/Formwork

Attachment1 ITP #/QCF, Formwork check list/QCF, Embedment check list

MS38Concrete to paved areas





Scope1 Purpose of this method statement, is to define procedure that shall be adopted for placing

concrete to paved areas.



Safety1 Safety Officer shall monitor and implement all HSE and environmental precautions.2 All persons, who are required to be involved on this activity, shall be made aware of all

safety issues relating to activity and situation.

Method1 Concrete Foreman shall check to establish that concerned paving areas are approved for

placement of concrete.2 Area in scope of pouring day shall be barricaded.3 Mockup shall be conducted as a representative sample to compare with all paving

concrete finish.4 Concrete foreman shall ensure that equipment required to place concrete are available at

worksite.5 Provision shall be made for emergency stop ends in case of batching plant or equipment

fail.6 Concrete Foreman shall order required concrete, advising batching plant of schedule and

type of concrete. 7 Fibre concrete is specified to be included for paving works.8 Concrete shall be tested by laboratory technician upon arrival at site.9 Placement of fibre concrete shall be carried out by approved method.10 Sequence of placement for fibre concrete shall be agreed with Engineer/EPC Contractor

engineer.11 Compaction by vibrator of fresh concrete shall be conducted under supervision of

concrete Foreman.12 Finish required to paved areas shall be as defined and presented on a mockup test panel. 13 Relevant finish shall be applied to paved area. 14 Attention to edges and finish shall be an important responsibility of concrete Foreman

and charge hand.15 Curing of fibre concrete shall be conducted in accordance with approved method

statement for curing concrete.

Equipment1 Concrete truck mixer/Concrete pump/Concrete skip/Compressor/Vibrators/Power

float/Finish templatesAttachment



Chapter 7 External Works & Utilities1 ITP #

MS39Excavation & backfill to structures


Scope1 Purpose of this method statement, is to define procedure that shall be adopted for

excavation and backfilling to structures.

Reference documents1 Specification- Excavation and Backfill for underground Installations


Method (sketch # 1-6/19 & all other related structures)Refer to sketches/Excavation

1 Project Site Engineer shall ensure that current drawings relating to excavation activity are approved for construction either by referring to updated version or inquiring DCC.

2 Project Site Engineer shall ensure that there are no conflicts with existing services or other discipline issues & that excavation details are in line to adequate constructability.

3 Surveyor shall provide line and levels that enable excavation for structure with all such marks clearly established on site to make further work convenient.

4 A system for quick reference from drawings shown details & site established points shall be established, so that working coordination remains intact without either under or over excavation.

5 Significant to remember that under excavation can be further excavated but, over excavation requires mass filling in principle, which would cost additionally.

6 Surveyor shall inform excavation Foreman respecting all these lines and levels, so that right site references are used & not allowed to be disturbed by site ignorant workers.

7 Excavation Foreman shall direct excavation equipment in an agreed sequence so that work moves in line to assumed or agreed sequence.

8 Excavated material shall be classified by laboratory test, which class or category it belon to.

9 Unsuitable material shall be removed off site to tip area, while suitable materials stocked separately for backfilling purpose.

10 Where material is classified as suitable, required volume shall be stockpiled on site in an agreed location.

11 All such materials as stock piles shall be prevented from causing site pollutions by flying away during fast blowing winds or during dust storms.

12 Safety barriers shall be erected as work proceeds to prevent workers from falling into trench.

13 Where applicable, sides of excavation shall be sloped, so that no danger from subsidence exists.



Chapter 7 External Works & Utilities14 Should restrictions be imposed by adjacent structures etc. that would make sloping of

sides unpractical, shoring or support of excavation side walls shall be agreed with EPC Contractor on site.

15 There is no requirement for ground dewatering equipment & if so required, adequate arrangement shall be made for continuous dewatering operation.

16 Surveyor and site engineer shall check excavation to confirm compliance with levels and lines.

17 A survey shall be conducted of formation level upon completion of excavation.18 Formation shall be visually inspected for unsuitable material, whether or not exists. 19 All such unsuitable material shall be removed from trench & if so required, soil

improvement may be resorted to or unsuitable material removed & replaced by suitable material duly compacted if acceptable, otherwise, mass concrete fill would be carried out for replaced unsuitable material.

20 Formation shall be scarified and compacted to required specification criteria. 21 Laboratory test results shall be provided for compaction test to ensure FDD. 22 Upon acceptance of these results, area shall be released for consequent activities for

blinding preparatory works.Backfill

1 Project site engineer shall ensure that all pre sequence activities are passed and completed.

2 Upon approval to start backfill, project/site engineer shall instruct Foreman to conduct this activity.

3 Backfill material shall be sourced from suitable material stockpile/imported as well from approved sourced, when stockpile is not available.

4 Backfill material shall be placed in layers according to provisions indicated on specification.

5 Backfill Layer shall be moisturized and compacted to agreed criteria respecting FDD.6 Each backfill layer shall be tested by test laboratory & test results provided. 7 An acceptable test result shall allow next layer of backfill to be placed and compacted. 8 This process shall continue, until structure backfilling is completed.9 Upon completion of backfill activity, involved area shall be cleaned of waste materials

and left tidy for moving to next activity.10 Safety barriers shall be removed to safety store.

Equipment1 Excavator/Dump truck/Compactors

Attachment1 ITP # Excavation and Backfill check list.


7 external utilities

Engineering