Highmast Lighting

METHOD STATEMENT
GERBANG PERDANA S B
(RoC No. 469478-X)
No. 3, Jalan 222,
For High Mast Lighting 46100 Petaling Jaya,
Selangor Darul Ehsan
Revision No. : 1.0

Issued : 01.06.2004
MS-CIQ06/E/018/R1.0
AUTHORIZATION AND RECORD
Rev. Description Prepared by Reviewed by Approved by Date

(Contractor) ( Consultant) (GP)
SIMON
1.0 FONG
2.0
Important
The information contained herein is proprietary to Gerbang Perdana Sdn. Bhd. It shall
not be reproduced, copied, revealed, published or distributed in whole or in part
without authorization.
______________________________________________________________________
TABLE OF CONTENTS
PAGE
REF DESCRIPTION
NO.
1.0 INTRODUCTION………………………………..………………… 2
2.0 SCOPE OF WORKS…………….………………………………… 2
3.0 WORK SEQUENCE FLOW……………………………………… 3
4.0 METHOD STATEMENT……………………..…………………… 4
5.0 MATERIAL………………….………………….…………………… 26
6.0 MACHINERY……………………………………………………… 26
7.0 MANPOWER……………………………………………………… 27
8.0 SAFETY & ENVIRONMENT………………..…………………… 27
9.0 INSPECTION & TEST PLAN…………………………………… 28
10.0 DIAGRAMS & DRAWINGS…………………..…………………… 28
METHOD STATEMENT
GERBANG PERDANA S B
(RoC No. 469478-X)
For High Mast Lighting No. 3, Jalan 222,
46100 Petaling Jaya,
Revision No. : 1.0

Issued : 01.06.2004
MS-CIQ06/E/018/R1.0
1.0 INTRODUCTION
The purpose of this method statement is to describe and defined the process
and flow sequence of high mast lighting installation and to suit the specified
requirements.
2.0 SCOPE OF WORKS

The electrical contractor for this project shall undertake the scope of supply,
delivery, installing, testing and commissioning and handling over procedure
that consist of cables, feeder pillars, pole, floodlights. The installation shall
meet with the tender specifications, approved shop drawings and authorities
requirement.
2
MSR FORMAT CM-MSR-01 (B)
METHOD STATEMENT
GERBANG PERDANA S B
(RoC No. 469478-X)
Revision No. : 1.0

Issued : 01.06.2004
MS-CIQ06/E/018/R1.0
3.0 WORK SEQUENCE FLOW

START
Submit Catalogue, Sample,

Technical data and
Specification for Approval
No Yes
Re-Submit as per Approved Issue Purchase order
requirement
Yes
Delivery to site visual
Method Statement and Shop inspected by QA/QC &
Drawing Submission Consultant Engineer
No Yes
Re-Submit as per Approved Preparation for installation
requirement
Yes
Installation as per Approved Yes

Method Statement and Shop
Drawing
Pre-Inspection
Remedy work
Final Inspection
END
3
METHOD STATEMENT
GERBANG PERDANA S B
(RoC No. 469478-X)
Revision No. : 1.0

Issued : 01.06.2004
MS-CIQ06/E/018/R1.0
4.0 METHOD STATEMENT for HIGH MAST LIGHTING

4.1 MAST BODY SECTIONS
4.1.1 Survey and pegged the position of the high mast lighting as per approved shop
drawing. Arrange the delivery of the material to site and place at suitable area.
The high mast hot-dipped galvanized steel mast presenting good visual
appearance acceptable to the engineer.
i) The high mast shall be 30m continuously tapered polygonal cross section.
The cross section shall be 20 sided polygonal in shape formed on brake press.
ii) No steel use will be made of structures derived from commercial tubes or
formed rolled sheets.
4.1.2 Arrangement of sections
4.1.2.1 Unload the sections and place them in the order of assembly and in
line so that the center of the assembled mast will be adjacent to the
column foundation, making due allowance for slip-joint overlap. This
will minimize crane handling time when erecting the assembled mast.
(See Fig. 1)
MAST COLUMN FOUNDATION (NO OF BOLTS DEPEND ON MT. HT.)
ACCESS DOOR
PACKING - COLUMN SECTION

CG FIG 1
BASE PLATE
4
METHOD STATEMENT
GERBANG PERDANA S B
(RoC No. 469478-X)
Revision No. : 1.0

Issued : 01.06.2004
MS-CIQ06/E/018/R1.0
4.1.3 Assembly of mast sections.
4.1.3.1 Arrange the base section with the access door facing upwards.
Ensure that the base plate is properly wedged to prevent rotation.
4.1.3.2 Position and level the remaining mast sections with sufficient timber
packing to ensure that sections are horizontal. (See Fig. 2)
ACCESS DOOR
FACING UP
ASSEMBLY DIRECTION
- GROUND LEVEL
PACKING
FIG 2
4.1.3.3 Begin assembly of sections from the base and work towards the top of
the mast.
4.1.3.4 Lubrication using linseed oil shall be applied to the slip-joint as follows:
i) The external surface of the lower section (male end) is coated to

approximately 75% of the slip joint length from the top end of the section.
The minimum slip joint for structural is identified by a marked red line. (See
fig 3)
ii) The internal surface of the upper section (female end) is coated to
approximately 75% of the slip joint length leaving the first 25% of slip-joint
length clear. (See fig 3)
iii) DO NOT USE any other type of lubricant as this may lead to a detrimental
appearance if runs or drips are formed.
4.1.3.5 Sling the section at its center of gravity and engage the sections,
making sure that the center line of the column is correctly aligned in
the horizontal and vertical planes. (See Fig 4)
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METHOD STATEMENT
GERBANG PERDANA S B
(RoC No. 469478-X)
Revision No. : 1.0

Issued : 01.06.2004
MS-CIQ06/E/018/R1.0
MARK 'RED LINE'

MALE SECTION SUP JOINT "L" FEMALE SECTION
0.25 L 0.75 L 0.25 L 0.75 L DIRECTION OF

ASSEMBLY
FIG 3
ACCESS DOOR CRANE ROFE

SLIP
FACING UP JOINT
ASSEMBLY DIRECTION
SLING
- GROUND LEVEL
PACKING
FIG 4
4.1.3.6 With TIRFORs attached to each side of the lower section and under
strict supervision, the TIRFORs are to operate in sequence to ensure
that telescoping of the sections is even about the mast axes. (See fig
5)
NOTE : BEFORE SECTIONS ARE PULLED TOGETHER, ENSURE THAT

THE SECTIONS ARE PROPERLY ALIGNED. MISALIGMENT FOR
ANY REASON MAY LEAD TO JAMMING AND PREVENT PROPER
TELESCOPING OF THE JOINTS AND PROVE DIFFICULT TO
RECTIFY.
6
METHOD STATEMENT
GERBANG PERDANA S B
(RoC No. 469478-X)
Revision No. : 1.0

Issued : 01.06.2004
MS-CIQ06/E/018/R1.0
i) During this operation, the external surface of the slip joint can be
hammered (using a wooden block as a buffer) with a sledge
hammer. DO NOT HAMMER DIRECTLY ON THE MAST AS
THIS WILL RESULT IN DAMAGE TO THE GALVANIZED
SURFACE.
ii) The sections must be joints until the minimum slip length is
achieved. However, jacking shall continue beyond the red line
until no further movement is possible.
4.1.3.7 A suitable length of rope equal to the mounting height of the mast is
to be progressively inserted along the length of each section as they
are being joined.
MIN. 5 TON
PULLER O
NOTES :
1. DO NOT HAMMER DIRECTLY
ON CALVANISED SURFACE
2. ALWAYS HAMMER ON A BLOCK
OF WOOD OR THE JOINT
MAY BE DAMAGED.
FIG 5
4.1.3.8 Repeat step 4.1.3.6 above for joining of subsequent sections of the
mast.
7
METHOD STATEMENT
GERBANG PERDANA S B
(RoC No. 469478-X)
Revision No. : 1.0

Issued : 01.06.2004
MS-CIQ06/E/018/R1.0
4.2 HEADFRAME and ACCESSORIES
The top section of the mast shall be equipped with a fixed type headframe. The
headframe assembly shall comprise the following:-
a) Headframe shall include a pulley system to accommodate three stainless steel

hoisting wire ropes at any one time and separate pulleys for the passage of flat
electrical cables. The pulley shall be of non-corrodible materials and shall run on self-
lubricating bearings with stainless steel axles.
b) A positive gravitational self-latching and unlatching system unaffected by dirt or

corrosion in service shall be incorporated in the design of the headframe so that
when the luminaire carriage ring is fully docked, the hoisting and winch wire ropes
shall be tension free. The complete headframe chassis shall be hot-dipped
galvanized. The use of multiple levers and springs being incorporated in the design
of the headframe is not permitted.
c) The self-latching and unlatching system must incorporate a flag indicator on the
headframe to alert the operator of when the system is latched or unlatched.
d) The high mast must also feature a latch indicator installed at the other service door
position to ensure the operator does not over-travel the mobile luminaire carriage
ring.
4.2.1 Before commencing to assemble headframe and accessories, ensure that the
top of the assembled mast is raised to a minimum of one meter above the
ground and packed with sufficient timber. The baseplate should be properly
wedged to prevent the mast from rotating with the access door facing upwards.
(See Fig 6)
4.2.2 The headframe is then placed at approximately 250-300mm distance apart from
the top of the mast with its flange facing the mast.
4.2.3 The headframe cover should be removed and the securing bolts restored to their
original position to facilitate easy retrieval during subsequent assembly.
8
METHOD STATEMENT
GERBANG PERDANA S B
(RoC No. 469478-X)
Revision No. : 1.0

Issued : 01.06.2004
MS-CIQ06/E/018/R1.0
ACCESS DOOR 250mm - 300MM

FACING UP
ASSEMBLY DIRECTION
1000mm
GROUND LEVEL
PACKING
FIG 6
4.2.4 Hoisting wire-rope
4.2.4.1 Wire ropes should be unrolled as shown in Fig 8 to avoid kinking or

twisting of the wire ropes. Faulty uncoiling will result in kinks being
formed in the wire-ropes and severely impair the safety level of the
wire-ropes. Arrange the base section with the access door facing
upwards. Ensure that the baseplate is properly wedged to prevent
rotation.
4.2.4.2 NEVER ATTEMPT TO STRAIGHTEN KINKS OR BENDS. ALWAYS

REPLACE THE DAMAGED WIRE ROPE. REFER TO SUPPLIER IF
REPLACEMENT OF FAMAGED WIRE-ROPE IS REQUIRED. DO
NOT SUBSTITITE ANY OTHER TYPE OR GRADE OF WIRE-ROPE.
4.2.5 Length of hoisting wire-ropes.
4.2.5.1 The cut end of each wire-rope shall be terminated with a thimble eye
and swaged copper ferrule. A 250kN press and dies to suit the ferrule
size are required. (See Fig. 8)
9
METHOD STATEMENT
GERBANG PERDANA S B
(RoC No. 469478-X)
Revision No. : 1.0

Issued : 01.06.2004
MS-CIQ06/E/018/R1.0
GALV. THIMLE
COPPER FERRULE
FIG 8
4.2.5.2 Ensure all completed wire-ropes are of EQUAL length.
4.2.6 Compensating disc assembly
4.2.6.1 Hoisting wire-rope should be individually marked with adhesive rape

on both ends to ensure that they can be easily identified to prevent
tangles.
4.2.6.2 Insert one end of each wire-rope through the top of the headframe as
shown leaving approximately 2 meters projecting (See Fig 9)
4.2.6.3 Insert electrical cable(s) through the cable pulleys provided, also
leaving approximately 2 meters projecting (See Fig 9)
4.2.6.4 Attach wire-rope to compensating disc assembly as shown.

Orientation “DOOR” of the compensating disc and headframe (marked
“DOOR”) should be maintained and wire-ropes should not be twisted.
(See Fig 10)
4.2.6.5 Assemble the electrical cable(s) to the L-bracket clamps provided on

the compensating disc assembly. The electrical cable(s) should also
be positioned/identified corresponding to the wire-rope position. (See
Fig 11)
10
METHOD STATEMENT
GERBANG PERDANA S B
(RoC No. 469478-X)
Revision No. : 1.0

Issued : 01.06.2004
MS-CIQ06/E/018/R1.0
WIRE ROPE
2
WIRE ROPE
COMPENSATING
DISC
WIRE
ROPE
1
TIMBER
SUPPORT
WIRE ROPE
3
FIG 9
ENSURE TWO GUIDE SLEEVES
ARE FACING UPWARDS
FIG 10
4.2.6.6 Using the rope inserted inside the mast earlier, tie the top end of the
rope (See Clause 2.7) to the compensating disc as shown (See Fig
12)
DOOR
FIG 11
11
METHOD STATEMENT
GERBANG PERDANA S B
(RoC No. 469478-X)
Revision No. : 1.0

Issued : 01.06.2004
MS-CIQ06/E/018/R1.0
FIG 12
4.2.6.7 Place the assembled compensating disc into the top of the mast with
the position marked “DOOR” facing the door orientation. From the
base of the mast, pull the other end of the rope to bring the
compensating disc assembly down towards the base of the mast.
(See fig 13)
PULL THE COMPENSATING DISC DOWN
FIG 12
4.2.7 Assembly of headframe to top of mast
4.2.7.1 Lift/position headframe (mark “DOOR” facing upwards) on the top

flange of the mast. Bolt the flanges together with the bolts provided.
(See Fig 14)
12
METHOD STATEMENT
GERBANG PERDANA S B
(RoC No. 469478-X)
Revision No. : 1.0

Issued : 01.06.2004
MS-CIQ06/E/018/R1.0
DOOR POSITION
D
BOTTOM FLANGE TO BE SECURED
ONTO TOP FLANGE OF MAST VIA
M16 SECURITY BOLTS
FIG 12
4.2.8 Assembly of carriage guide
4.2.8.1 Insert thimble end of the wire-rope through the top of the guide sleeve
of the headframe (See Fig 15)
4.2.8.2 Remove one of the safety cotter pins together with the stainless steel
pin from the carriage guide.
4.2.8.3 Insert the thimble end of the wire-rope through the centre of the
carriage guide to the position of the stainless steel pin.
4.2.8.4 Restore the stainless steel pin to its original position through the
thimble end of the wire-rope (See Fig 16)
4.2.8.5 Secure the safety cotter pin on the stainless steel pin as shown.
(See Fig 17)
4.2.8.6 Place the carriage guide inside the guide sleeve but DO NOT latch
into position.
4.2.8.7 Repeat steps 4.2.8.1 to 4.2.8.6 above for remaining carriage guides.
13
METHOD STATEMENT
GERBANG PERDANA S B
(RoC No. 469478-X)
Revision No. : 1.0

Issued : 01.06.2004
MS-CIQ06/E/018/R1.0
GUIDE SLEEVE
LATCH
WIRE ROPE
CARRIAGE GUIDE
SHOWING INSERTION OF HOISTING WIRE ROPE

THROUGH GUIDE SLEEVE FIG 15
SAFETY COTTER PIN
GUIDE SLEEVE
LATCH
STAINLESS STEEL PIN

WIRE ROPE
SAFETY COTTER PIN
STAINLESS STEEL PIN

FIG 16 FIG 17
4.2.9 ASSEMBLY OF RING CARRIER
4.2.9.1 Remove the bolt from the ring carrier to disengage cable guide and
clamp.
4.2.9.2 Insert pipe end of ring carrier through the carriage guide. (See fig 18)
4.2.9.3 Restore the cable guide and clamp to its original position and tighten
with the bolt and nut provided.
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METHOD STATEMENT
GERBANG PERDANA S B
(RoC No. 469478-X)
Revision No. : 1.0

Issued : 01.06.2004
MS-CIQ06/E/018/R1.0
4.2.9.4 Repeat steps 4.2.9.1 to 4.2.9.3 above for the other two ring carriers.
WIRE
ROPE
GUIDE SLEEVE WIRE ROPE

PULLY
CABLE GUIDE CABLE CLAMP
SHOWING CONNECTION OF RING CARRIER

TO CARRIAGE GUIDE
FIG 18
4.2.10 Assembly of carriage ring
a) The lantern carriage ring shall be of steel construction and manufactures in three
segments. The unit shall be joined by bolted flanges. Proper lantern carriage ring
support arms shall be provided for supporting the lantern carriage ring when the latter
is lowered for maintenance.
b) The mobile luminaire carriage shall be designed to carry the assigned number of
luminaires and control gears and shall be evenly balanced. Nylon paddle guide ring
shall be incorporated as a buffer arrangement between mobile luminaire carriage and
mast shaft. This is the prevent damaged to mast surface during raising and lowering
operation of mobile luminaire carriage.
c) There should be provision for fixing obstruction light and lightning arrestors,
calculations for the wind load and static load effects shall be based on the required
number of luminaires.
15
METHOD STATEMENT
GERBANG PERDANA S B
(RoC No. 469478-X)
Revision No. : 1.0

Issued : 01.06.2004
MS-CIQ06/E/018/R1.0
4.2.10.1 Assembly carriage ring segments to ring carrier as shown with the
securing bolts provided. Do not fully tighten the bolts until all the ring
segments have been connected.
4.2.10.2 Check that carriage ring segments are properly secured in place and
tighten all the securing bolts. (See Fig 19)
CARRIAGE RING
RING CARRIER
ASSEMBLY OF CARRIAGE RING

FIG 19
4.2.11 Assembly of guide ring
4.2.11.1 Bolt one half of the guide ring to the cable clamp (attached to
the ring carrier) with the countersunk bolts provided as shown.
(See fig 20)
4.2.11.2 Join the remaining half of the guide ring to make a complete
ring (See Fig 21)
4.2.11.3 Secure the guide ring at the two remaining cable clamp
positions. (See Fig 22)
4.2.11.4 Tighten the countersunk bolts when the guide ring is in place.
16
METHOD STATEMENT
GERBANG PERDANA S B
(RoC No. 469478-X)
Revision No. : 1.0

Issued : 01.06.2004
MS-CIQ06/E/018/R1.0
CABLE CLAMP
GUIDE RING
FIG 20
FIG 21 FIG 22
4.2.12 Assembly t latch indicator
4.2.12.1 The latch indicator is preset in the factory before shipment.
4.2.12.2 Bolt the flag indicator to the headframe as shown (See Fig 23)
LATCH INDICATOR GUIDE SLEEVE
FIG 23
17
METHOD STATEMENT
GERBANG PERDANA S B
(RoC No. 469478-X)
Revision No. : 1.0

Issued : 01.06.2004
MS-CIQ06/E/018/R1.0
4.2.13 Winch mounting bracket
Each mast shall be provided with double drum winch of minimum safe working load
750kgs suitable for raising and lowering the luminaire carriage ring and its latching
mechanism. Drums shall be grooved type.
The winch must be of robust design and manufactured to have a “non-slip and fully
self sustaining” feature. The reduction gear of the winch shall be of self locking worm
gear operating in an oil bath. The winch shall not be dependent on brake and
restraining device in the event of total failure of this device.
The capacity and operating speed of the winch shall be clearly marked on each
winch on an indelible label together with the specification of the recommended
lubricant.
The hoisting winch shall be driven by variable speed reversible power operated tool.
Raising and lowering operation shall be via a remote control system to allow the
equipment to be operated from approximately five meters away from the column. The
motor provided for the winch shall be capable of raising and lowering the total
connected load without any difficulty and shall be dismountable from the winch. The
carriage movement shall be smooth without sudden jerk.
The type of electrical power operated tool for winch shall be specified in the
submission of tender, and shall be clearly made known to the engineer of the project.
The winch drive unit shall be a squirrel cage, reversible induction type motor. It shall
be complete with a flange for coupling onto the winch to facilitate detachment and
attachment on several masts in succession. In addition, the motor shall have the
following characteristics:-
i) 415V 3 Phase 50Hz

ii) Class B Insulation
iii) The motor should be suitable for tropical operation
iv) Protection degree IP55
The winch power drive unit shall include built in safety feature to prevent the
possibility of excessive torque being applied to the winch shaft. These are:-
a) A factory pre-set electronic torque limiting device for immediate shutdown of power
in the drive motor in the event that the luminaire carriage ring reaches its end travel.
18
METHOD STATEMENT
GERBANG PERDANA S B
(RoC No. 469478-X)
Revision No. : 1.0

Issued : 01.06.2004
MS-CIQ06/E/018/R1.0
b) A shear pin, which fails within predetermined torque, limits above safe levels.
c) An electrical limit switch to cut off electrical supplied to the motor.
4.2.13.1 Insert winch mounting bracket into column through the access
door at the bottom of the mast.
4.2.13.2 Bolt the winch mounting bracket to the mast with the bolts
provided. (See Fig 24)
WINCH BRACKET
WINCH BRACKET
FIG 24
4.2.14 Assembly of winch
4.2.14.1 Bolt winch to the winch mounting bracket with the bolts
provided. Ensure the input shaft is facing the access door (See
Fig 25)
4.2.14.2 Insert winch into the column through the access door at the
bottom of the column
4.2.15 Assembly of winch wire-ropes to compensating disc assembly.
4.2.15.1 Remove the temporary rope from the compensating disc. Disc
not allow the disc to turn as this will result in the hoisting wire-
ropes entangling or crossing.
19
METHOD STATEMENT
GERBANG PERDANA S B
(RoC No. 469478-X)
Revision No. : 1.0

Issued : 01.06.2004
MS-CIQ06/E/018/R1.0
WINCH BRACKET
WINCH
FIG 25
4.2.15.2 Attach the winch wire-ropes to the compensating disc as

shown. The position marked “DOOR” on the compensating
disc should be facing the access door. (See Fig 26)
WINCH WIRE ROPE COMPENSATING

BALANCE LEVER
DISC
DOO
R
FIG 26
4.2.15.3 Ensure that all hoisting wire-ropes are properly seated on the
respective wire-rope pulleys.
4.2.15.4 Manually turn the winch output drive until the carriage guide is
firmly located in the guide sleeves.
20
METHOD STATEMENT
GERBANG PERDANA S B
(RoC No. 469478-X)
Revision No. : 1.0

Issued : 01.06.2004
MS-CIQ06/E/018/R1.0
4.2.15.5 Ensure that the hoisting and winch wire-ropes are taut. Double
check that the hoisting wire-rope remain seated in the wire-
rope pulleys.
4.2.16 Installation of electrical cable(s)
Electrical cable shall be anti-twist flat flexible cable suitable for very small bending
radial. Standard flexible electrical cable with 2.5mm2 conducting area shall be
provided for connecting of power supply to the light source and shall terminate at the
stationary connecting box in the base compartment with a weather-proof multipin
socket fitted with a locking device. At the headframe, electrical cable shall be
connected to a weather proof junction box complete with a weather-proof plug and
socket with locking device which is mounted on the luminaire carriage ring.
4.2.16.1 Insert the electrical cable(s) through the cable guide and clamp
located on the guide ring. Pull the cable taut and ensure it is
properly seated in the pulleys. (See Fig 27)
CABLE
CABLE PULLEY
ALLOW 50-60mm
SLACK
FIG 27
4.2.16.2 Allow approximately 50-60mm slack in the cable from its taut
position as shown in figure. At this position, tighten the cable
between the insulation plates on the cable clamp.
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METHOD STATEMENT
GERBANG PERDANA S B
(RoC No. 469478-X)
Revision No. : 1.0

Issued : 01.06.2004
MS-CIQ06/E/018/R1.0
4.2.17 Completion of mast assembly
4.2.17.1 The headframe cover can now be restored to its original

position and the bolts tightened.
4.2.17.2 Secure two non-elastic ropes to the baseplate and the carriage
ring, diametrically opposite each other.
4.2.17.3 Check and ensure that all bolts are properly tightened.
4.2.17.4 The mast is now ready for erection.
4.3 ERECTION OF MAST
4.3.1 Preparation
4.3.1.1 Using a spirit, level four of the foundation nuts diametrically opposite
at 90° until all four nuts are at the same level. (See Fig 28)
LEVELLER
ADJUST NUTS
130 - 150 mm
FIG 28
4.3.1.2 Lower the rest of the nuts at least 10-15mm lower than the four
reference nuts. (See Fig 29)
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METHOD STATEMENT
GERBANG PERDANA S B
(RoC No. 469478-X)
Revision No. : 1.0

Issued : 01.06.2004
MS-CIQ06/E/018/R1.0
10mm
10mm
PVC PIPE FOR CABLE EXIT

FIG 29
4.3.2 Criteria for lifting equipment
4.3.2.1 The mobile crane should have a minimum lifting capacity of 35 tonnes
but shall be decided by the crane crew upon inspecting site
conditions.
4.3.2.2 The boom shall be long enough to suspend mast vertically.
4.3.3 Crane position
4.3.3.1 The ideal position for crane is as shown. (See Fig 30)
4.3.3.2 The recommended sling position is 75% of the mast height measured
from the base.
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METHOD STATEMENT
GERBANG PERDANA S B
(RoC No. 469478-X)
Revision No. : 1.0

Issued : 01.06.2004
MS-CIQ06/E/018/R1.0
NOTE CRANE POSITION AND LIFTING POINTS ARE SUBJECT TO SITE

CONDITIONS AND SHALL BE DETERMINED ON SITE.
COLUMN
FOUNDATION
= 3/4 OF MAST COLUMN LENGTH
BASE PLATESLING
CRANE
FIG 30
4.3.3.3 Before lifting the mast into position, mark the baseplate and the
foundation to ensure that the headframe is correctly aligned to the
required lighting array.
4.3.3.4 If necessary, rotate the mast on its packing prior to lifting to facilitate
the alignment.
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METHOD STATEMENT
GERBANG PERDANA S B
(RoC No. 469478-X)
Revision No. : 1.0

Issued : 01.06.2004
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4.3.3.5 Ensure that the crane jib will be below the headframe when the mast
is raised.
4.3.4 Foundation bolts
4.3.4.1 When the mast is properly located over the foundation bolts, fit the
nuts and washers to the four reference bolts.
4.3.4.2 Check vertical alignment of the mast with a theodolite and if necessary
adjust the reference nuts on the underside of the baseplate.
4.3.4.3 When the mast is vertical, tension the nuts (APPENDIX III). KEEP
THE MAST SUSPENDED ON THE CRANE UNTIL THIS
OPERATION IS COMPLETED.
4.3.4.4 Fit the remaining nuts and washers and torque down.
4.3.4.5 Fill the space beneath the baseplate with grout. Use a length of
conduit, pipe or bar to make a drain through the grout.
4.3.4.6 Complete the installation with fixing the approved reflective stickers on
the pole for labeling purposes.
4.3.5 Concrete foundation shall be design by Civil & Structural Engineer.
25
METHOD STATEMENT
GERBANG PERDANA S B
(RoC No. 469478-X)
Revision No. : 1.0

Issued : 01.06.2004
MS-CIQ06/E/018/R1.0
5.0 MATERIAL
5.1 Materials
a) 30 meter Hot Dipped Galvanized Iron Pole
b) Armoured cables
c) Feeder Pillars
d) GI Pipes
e) Flood Lights
f) Cable Marker
h) Bricks and Sands
5.2 Tools
a) Wrench set
b) Electrical Tools
c) Hammer & Chisel
d) Cable Roller
e) Screw Driver & Spanner
6.0 MACHINERY
6.1 Crane
6.2 Excavator
6.3 Compactor
26
METHOD STATEMENT
GERBANG PERDANA S B
(RoC No. 469478-X)
Revision No. : 1.0

Issued : 01.06.2004
MS-CIQ06/E/018/R1.0
7.0 MANPOWER
7.1 Engineer
7.2 Supervisor
7.3 Electricians
7.4 QC Inspector
7.5 General Worker
7.6 Crane Operator
8.0 SAFETY & ENVIRONMENT

8.1 Safety
The following item are deemed the safe working practice and should
be observed by all workers as well as sub contractor’s workmen who
are engaged to carry out within the company’s or its client’s premises.
i. Wear Plain, tough, close-fitting clothing and keep them buttoned

up.
ii. Wear Safety shoes or boots and keep them in good repair.
iii. Wear Hand gloves when holding objects which are hot, sharp
edged, covered with chemical or oily surface.
iv. Wearing safety helmet at construction site.
v. Use ears protection devices and masks where necessary.
vi. In additional, the personnel protection equipment shall be
practice all the time such as wearing Safety Helmet, Safety
Shoes, Eye Goggles, Safety belt, welding Mask and etc.
8.2 Environment
All workers shall be responsible and ensure that the site works carried
out shall conform with the Employer’s Environment Policy and comply
with the Malaysian Environment Act 1974 and any other Federal and
27
METHOD STATEMENT
GERBANG PERDANA S B
(RoC No. 469478-X)
Revision No. : 1.0

Issued : 01.06.2004
MS-CIQ06/E/018/R1.0
State Government act. Hence always all workers shall ensure that all
the site workers shall;
i. Any waste and unwanted installation materials arising from the

works is not harmful and does not cause deposits and
contamination in drains and sewers.
ii. Keep roads and footpaths clear of mud, unwanted installation
debris, boxes and the like. Cooperates with Main Contractor and
Employer on this respect.
iii. Ensure that existing services are not damaged and are
maintained in good order.
iv. Take effective action prevent occupies of adjacent buildings or
land, and the general public from any danger, discomfort,
disturbances, trespass or nuisance.
v. Take effective measures to reduce nuisance from dust during
the site installation works.
vi. Take effective measure to minimize the noise from the
installation works.
9.0 INSPECTION & TEST PLAN
All work-in- progress shall be inspected by the designated project staff

and the site resident engineer / site clerk of work at various inspection
points as per the relevant project quality plan. Refer to the
attachment.
10.0 DIAGRAMS & DRAWINGS

Drawing no./ description :
1) SD/GSB/ICIQ/CIQ/EE/2500 – External Lighting Layout 1
2) SD/GSB/ICIQ/CIQ/SLD/1256 – Single Line Drawing for External
Lighting Feeder Pillar
3) SD/GSB/ICIQ/CIQ/GEN/0071 – Detail of 30m High Mast Lighting
28
GERBANG SELATAN BERSEPADU PROJECT
INSPECTION CHECK-LIST OF CONTRACTOR (ICC) (469478-X)
REF. NO.: to follow the relevant RIN no. D ATE: 1/6/2004
Discipline: Electrical
Delete which are not applicable
Trade/Service: HIGH MAST LIGHTING INSTALLATION

Service
Item: Location/Level:
items to be check area
Acceptability
No. Item to be Checked Remarks
Yes No
1 Material Type / Size
2 Quantity
3 Securely Fitted
4 Alignment
5 Levelling
6 Inspect for Mechanical Damages
7 Cabling Routing
8 Spacing
Checked by : (Contractor) Verified by : (Consultant) Approved by : (GPSB's Rep.)
Sign./ Stamp Sign./Stamp Sign./Stamp

Name Name Name
Date Date Date
ISSUED DATE: 1 June 2004 FORM REF.: CM-RIN-01 (CONT INSP)

PAGE 1 OF 1 .
REVISION: 1.0 INSPECTION CHECK-LIST OF CONTRATOR (ICC)

Highmast Lighting

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METHOD STATEMENT

Revision No. : 1.0

AUTHORIZATION AND RECORD

Rev. Description Prepared by Reviewed by Approved by Date

Revision No. : 1.0

2.0 SCOPE OF WORKS

Revision No. : 1.0

3.0 WORK SEQUENCE FLOW

Submit Catalogue, Sample,

Installation as per Approved Yes

Revision No. : 1.0

4.0 METHOD STATEMENT for HIGH MAST LIGHTING

4.1.2 Arrangement of sections

MAST COLUMN FOUNDATION (NO OF BOLTS DEPEND ON MT. HT.)

PACKING - COLUMN SECTION

Revision No. : 1.0

4.1.3 Assembly of mast sections.

i) The external surface of the lower section (male end) is coated to

Revision No. : 1.0

MARK 'RED LINE'

0.25 L 0.75 L 0.25 L 0.75 L DIRECTION OF

ACCESS DOOR CRANE ROFE

NOTE : BEFORE SECTIONS ARE PULLED TOGETHER, ENSURE THAT

Revision No. : 1.0

Revision No. : 1.0

4.2 HEADFRAME and ACCESSORIES

a) Headframe shall include a pulley system to accommodate three stainless steel

b) A positive gravitational self-latching and unlatching system unaffected by dirt or

Revision No. : 1.0

ACCESS DOOR 250mm - 300MM

4.2.4 Hoisting wire-rope

4.2.4.1 Wire ropes should be unrolled as shown in Fig 8 to avoid kinking or

4.2.4.2 NEVER ATTEMPT TO STRAIGHTEN KINKS OR BENDS. ALWAYS

4.2.5 Length of hoisting wire-ropes.

Revision No. : 1.0

4.2.5.2 Ensure all completed wire-ropes are of EQUAL length.

4.2.6 Compensating disc assembly

4.2.6.1 Hoisting wire-rope should be individually marked with adhesive rape

4.2.6.4 Attach wire-rope to compensating disc assembly as shown.

4.2.6.5 Assemble the electrical cable(s) to the L-bracket clamps provided on

Revision No. : 1.0

Revision No. : 1.0

PULL THE COMPENSATING DISC DOWN

4.2.7 Assembly of headframe to top of mast

4.2.7.1 Lift/position headframe (mark “DOOR” facing upwards) on the top

Revision No. : 1.0

4.2.8 Assembly of carriage guide

Revision No. : 1.0

SHOWING INSERTION OF HOISTING WIRE ROPE

SAFETY COTTER PIN

STAINLESS STEEL PIN

STAINLESS STEEL PIN

4.2.9 ASSEMBLY OF RING CARRIER

Revision No. : 1.0

GUIDE SLEEVE WIRE ROPE

SHOWING CONNECTION OF RING CARRIER

4.2.10 Assembly of carriage ring

Revision No. : 1.0

ASSEMBLY OF CARRIAGE RING

4.2.11 Assembly of guide ring

Revision No. : 1.0

4.2.12 Assembly t latch indicator

4.2.12.1 The latch indicator is preset in the factory before shipment.

LATCH INDICATOR GUIDE SLEEVE