1.

PURPOSE
The purpose of this Method Statement is to provide General Guidelines for Cable laying &
Cable Termination for the Project PE # 434 : Power, Control & Signal Cables for The Scrap
Pellet recovery project for Abu Dhabi Polymer Company Ltd. (BOROUGE) at the Ruwais
Industrial Area, Abu Dhabi Emirate.

2. SCOPE
Scope of this Method Statement covers the following activities.
 Material Handling
 Procedure
 Precautions
 Testing
 Inspections

3. REFERENCES
The Following documents & drawings are considered for reference documents:
 Project Specific Cable Route drawings. {please indicate specific drawing references}
 Project Specifications
 Project Quality Plan (PQP)
 Inspection & Test Plan(ITP)

4. DEFINITIONS
OWNER: Abu Dhabi Polymer Company ltd. “BOROUGE”
ENGINEER: {please indicate Consultant/Engineer’s name.}
CONTRACTOR: Al Husam General Contracting Est.
DAY: A consecutive calendar day unless otherwise stated
MAY: Is used where a provision is discretionary
PLANT: Machinery, computer hardware and software, apparatus, materials, articles
and things of all kind to be provided under the contract other than
Contractor’s Equipment.
PROJECT: Project PE #434 Scrap Pellet recovery project for Abu Dhabi Polymer
Company Ltd. (BOROUGE)
SE: Site Engineer
SUP: Supervisor
ITP: Inspection & Test Plan
E&I: Electrical & Instrument
QA/QC: Quality Assurance and Control
IFC: Issued for Construction
PPE: Personal Protective Equipment
HSE: Health Safety & Environment

5. MANPOWER & EQUIPMENT

5.1 MANPOWER

5.1.1 PROJECT MANAGER :

 The Project Manager has the overall administrative responsibility for the implementation
of this method statement.
 Coordinates the works with the Site Manager to ensure they are carried out according to
the planned program.

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  Conveys to the Site Manager the importance of adhering to all safety measures and
quality control in co-ordination with Safety Engineer and QC Engineer and in line with
the HSE Plan and Quality Plan.

5.1.2 Site Manager :

 The Site Manager has the overall site responsibility for the implementation of this
method statement.
 Ensures that approvals from all concerned authorities has already been obtained before
proceeding with trial pit excavation and made available to his site team.
 Ensures that the works are carried out according to the planned program and that all the
equipment required to execute the works shall be available as per the project planning
and are in good condition.
 Coordinates with the Project Engineer / Site Engineer, Safety Engineer, Quality Control
Engineer and for the orderly, safe and proper execution of the work.
 Specific attention shall be given to all safety measures and quality control in co-
ordination with Safety Engineer and QC Engineer and in line with the HSE Plan and
Quality Plan.

5.1.3 Project Engineer / Site Engineer:

 Ensures that all the works are to be carried out according to the specifications and
approved shop drawings.
 Provides all necessary information and assigns the responsibilities to his construction
team.
 Ensures and monitors the work progress of work in accordance with the required
program and report the same to the Project Manager.
 Coordinates with the Safety Engineer to ensure that the works are carried out in a safe
working practice.
 Coordinates with the QA/QC Engineer for the tests (if any) to be carried out and initiates
for the inspection for the work activities.
 Ensures the implementation of any request that might be raised by the Consultant.
 Coordinates with the site foreman and plans the works in advance as per the work
sequence.

5.1.4 Surveyor:
 Shall ensure that New Abu Dhabi Datum reference survey points/markers are obtained
and located at or near the work site.
 Shall ensure that all coordinates values are in WGS 84-UTM, Zone 39N Coordinate
System.
 Shall ensure that existing buried services are already located, identified and exposed
prior to excavation.
 Shall supervise the checking of trench depth and grade (as may be required) during
excavation.

5.1.5 HSE Engineer/Officer:

 Ensures the implementation of all Safety measures in accordance with the HSE plan and
ensures that everybody is fully aware of it for safe work implementation.
 Ensures all the implemented safety measures are adequate to maintain the safe working
environment on site.

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  Inspects all the site activities and trains the persons to prevent incidents and avoid
accidents and to properly report any incidents and accidents to the Project Manager and
Consultant.
 Ensures that the site is maintained clean, tidy and free of obstacles that could endanger
safety.

5.1.6 QA/QC Engineer:

 Ensures that all the required permits and clearance are already obtained and still valid
before starting the work.
 Maintains inspection and test records complete for any future reference.

5.1.7 Other Personnel requirement:

i. Technicians
ii. Helpers
iii. Banks men
iv. Fork lift operator
v. Crane Operator
Whose responsibilities include
 Follow Safety Rules & Regulations
 Report any hazard in work place
 Report any accident or near miss
 Identify risks in workplace and associated hazards
 The usage of issued PPE
 Report any defects in machinery and equipment
 Report any non-conformance identified at work site

5.2 Equipment / Tools

{Please add or delete equipment according to site requirement}
a) JCB Excavator
b) Hi-Up
c) 20 Ton Mobile Crane
d) Plate Compactor
e) Cable Rollers
f) HV Cable Joint Kit
g) Cable Trolley
h) Crimping Press
i) Cable Pulling Winches
j) Transportation vehicle
k) Portable Lights
l) Jointer Tool Box
m) Electrical Tool Box
n) H.V. Cable Saw
o) AC High Voltage Test Kit / VLF Test Kit
p) Manual Excavation Tools
q) Removable Barricades

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6. PROCEDURE

6.1 EXCAVATION & BACKFILLING

6.1.1 PREPERATION & PRECONDITIONS

a) Permit to Work (PTW) if required shall be raised to the Owner/Engineer for the
excavation clearly mentioning the location of work, size of excavation and levels.
b) Excavations area shall be surveyed and marked to the lines and levels as shown on the
drawings.
c) The area of excavation will be cordoned off using safety barricading to stop trespassers.
d) Assign sufficient banks men, helpers and supervisors at the site prior to start of
excavation.
e) Required sign boards such as “DEEP EXCAVATION” “MEN WORKING”, “DANGER” and
warning boards will be placed to indicate the excavation work.
f) Ensure the working area at any confined space is free from any Hazardous Gas by proper
Gas testing using the Gas testing instrument.
g) If there are structures adjacent to the work area, proper temporary supports shall be
provided to the adjacent structure prior to start excavation.
h) Fences and minor structures of any character or upon within the limits of the works and
not necessary for the construction shall be removed carefully and stored neatly for
reinstating after the construction works.
i) If any Survey points, bench marks, boundary stones and markings falling on the area
shall be removed only with the OWNER / ENGINEER's written consent and shall be stored
and reinstated according to OWNER / ENGINEER's instructions.
j) Check the area of excavation to find out any underground facilities other than listed in
topographical survey by:
 Using appropriate detective equipment, such as cable detector, metal detector
etc.
 Check existing exposed excavation nearby area to find out existing underground
facilities.
 Refer available As-built drawings from the Company, other agencies, other
contractors doing projects nearby areas and mark in the area.
 Take trial/ test pits to find out existing underground pipes, structures.
 Check the indication marks, signs, manholes nearby area and find out the path of
services.

6.2 EXCAVATION

6.2.1 Trial Pit and Excavation Procedures

a) Prior to star of any excavation, the area shall be checked for the existing services/ utilities
by obtaining the approvals with reference to the relevant drawings.
b) The necessary excavation activities shall start only after getting the notice intent from
the Concerned Authorities who have services /installation in the vicinity or plan to install
their services in the general area in the near future.
c) Excavation of the trial pits shall be done manually as per the size indicated in the
approved drawings up to the required length and level.
d) In open areas the excavation shall be carried out by using the machineries, the exact
location of each trench and pit being subjected to the prior approvals.
e) Manual excavation will be carried out to expose the existing utilities, if any, which has to
be identified.

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 f) The trenches shall be kept dry during cable installation operation. The contractor shall
deal with the dispose of water so as to prevent any risk to the cables and other
materials.
g) The contractor shall provide suitable dewatering while performing the works according
to the scope of work.
h) The required control measures shall be developed and implemented while performing
the works and more importance will be given for public safety and environmental issues.
i) While performing the work the trenches shall be straight, free from any sharp
objects/edges likely to injure the cable or accessories and filled with soft sand and sieved
sand to form smooth bedding before the cables are laid.
j) The contractor shall take the necessary precautions to prevent damage to the road or
ground surface due to a slip or breaking away from the side walls of the trench including
the pedestrian safety as well.
k) The vehicle entry shall be restricted on the specified work area by prior approval from
the concerned agencies.
l) Where ever there is a crossover of the existing services/utilities, these shall be protected
with utmost care with the prior permission of concerned authorities and approved
methods.
m) In case of other projects in the same vicinity, the contractor shall obtain the necessary
approval from the Owner/Engineer & the Engineer for the concerned project to clarify
the scope of the works and boundaries of the other project, according to the scope of
the work.
n) Excavate the area by using only hand tools as per the markings and levels with proper
protection of sides
o) The bottom of the excavation shall be levelled and trimmed to receive the permanent
works.
p) Provide proper rigid barriers around excavations include provision of ladders, emergency
escape way, adequate side slopes or shoring and shuttering, detours.

6.2.2 EXCAVATION ADJACENT TO UNDERGROUND SERVICES

a) Excavation near the existing electrical cables, instrumentation and control cables, sewer
line, gas lines and any other service line shall take all necessary precautions to protect
the services with proper supports & covers.
b) All existing structures, foundations, pipes and cables, if any, which are to be incorporated
into the final work, shall be adequately protected from damage.
c) All underground services located during excavation shall be mapped for consideration
during construction of the works.
d) If any underground service is noticed other than specified in the area during excavation
shall be brought in notice of the OWNER
e) Excavation shall not be carried out adjacent to or near existing building foundations,
without suitable shoring/sheet piling.

6.3 BACKFILLING
6.3.1 General

a) Backfilling area shall be backfilled with approved material compacted in layers by

suitable equipment like plate compactors, vibratory roller compactors, etc., until the
specified density has been obtained to the satisfaction of the OWNER/ ENGINEER.
b) Compacting shall be carried out with special care by means of mechanical tampers of a
type approved by OWNER/ENGINEER to avoid damage to structures.

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 6.3.2 BACKFILLING MATERIALS

a) Backfilling materials shall be free from stones or rocks larger than 50 mm, or other
material which might prevent proper compaction or cause the compacted fill or
embankment to perform inadequately.
b) Backfilling materials shall be free from fossil content, clay, vegetation and its roots, waste
materials, Material containing gypsum or other soluble salts greater than the allowable
limits.
c) Following classified materials shall not be used for backfilling.
• Organic material, logs stumps and perishable materials.
• Material susceptible to spontaneous combustion.
• Materials with undefined properties.
• Materials having moisture content greater than the maximum specified.
• Building rubble and domestic and industrial wastes.
• Soils and rock susceptible to deterioration/change of their properties.
• Clay, silt and other loose or soft soils not in accordance with compaction criteria.
• Dredged material.
• Rock materials

6.3.3 FILLING OF MATERIALS

a) Fill material shall be spread and compacted in 300 mm layers, with a compacted layer
thickness not exceeding 300 mm where mechanical compactors like vibratory
plate/drum compactors are used.
b) The thickness of fill material shall not exceed 150 mm where manual compaction
methods are adopted.
c) If the thickness of loose fill layers required to exceed 300 mm written approval including
methods of compaction shall be required from the OWNER/ENGINEER.
d) If the surfaces receiving fill layers is smooth, then scarified to obtain a good friction/key
between the new fill layer and the sub grade.
e) Excavated materials may only be used for backfilling after obtaining necessary
permissions or approvals from the Owner/Engineer.

6.4 Formation of Cable Trench.

a) The formation of the trench shall be in accordance with Project Drawings and
Specifications.
b) The trench shall be excavated upto the required depth of 0.76 Mtr. from the existing
ground level
c) Dune sand bedding shall be done for a thickness of 150mm at the bottom of the trench
using TR tested and approved dune sand, prior to the installation of cables.
d) Cables are laid over the dune sand bedding
e) Approved sand/backfill material is filled in the trench to the required level as per
approved drawing.
f) Sufficient Water is poured to match the required Moisture content
g) Cable protection tiles are laid above the dune sand filling

6.5 Final Backfilling.

a) Ensure the Concrete Cable Tiles are securely placed.

b) Selected sieved materials from the excavated soil shall be backfilled for a thickness of
250mm above the cable protection tiles. Care shall be taken to avoid stones and
boulders mixing with the backfill material

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 c) Install Cable Warning Tape at a height of 250mm from top of the concrete cable tiles
d) Backfill to the required level in similar way.
e) Ensure Proper Compaction of soil is done after every 150mm layer laid.
f) Reinstate the area as to its original situation.

7.0 CABLING
7.1 Material Handling

a) The Material RECEIVED FROM Client shall be stored in designated area of the
Store/storage facility.
b) Arrangements shall be made to protect the cable drums against effects of weather and
environment.
c) Material inspection will be carried out to ascertain that no damage has occurred to the
Cables.
d) In case of any damages common inspection and report will be issued.
e) Cable shall be tested on cable drums prior to removal and work site with a 1000 V
insulation tester (5KV for MV Cables).The values will be noted for Core to Core and
Armour.
f) After the test, the end of the cable shall be sealed to prevent the ingress of moisture.
g) Store material requisition shall be made.
h) The material shall be transported in their original packing to location.
i) The cable drums shall be off-loaded at the site locations as identified by the site
engineer.
j) It shall be ensured that there is no obstruction to movement of vehicles or any hindrance
to works of other companies.

7.2 Cabling

7.2.1 Underground Cable Pulling

a) Inspection of sand bed will be carried out prior to commencement of cable pulling. The
sand bed will be of minimum 100mm Thickness.
b) After commencement of cable pulling the trench will be maintained clean.
c) Cable rollers shall be placed as required on the cable route.
d) Cable winch, if required, shall be positioned in proper place for cable pulling.
e) The cable drum intended for cable pulling shall be identified as per that indicated in the
drum schedule.
f) The cable drums shall be un-packed.
g) The cable shall be fixed to the winch, if used, by means of a cable sock or gripper.
Required number of persons will be posted at winch and near the drum.
h) Cable laying will generally start from one end of the route length or at any suitable point
if required.
i) In case of buildings, the drums will be placed outside the buildings and the cable pulled
in the opposite direction. After reaching the other end the length of the cable required
for reaching the location inside the building will be measured and then cut the cable.
j) In case of cable lengths which are more than one drum length, all cables which can be
laid from original position will be completed. And then the cable pulling set-up will be re-
positioned to the next location, from where the next length will be pulled.
k) Depending on the weight and size of the drum, suitable size of the cable spindle shall be
placed inside the central axis of the drum.
l) Suitable jacks shall be placed firmly on the ground and jacked-up to allow clearance from
the ground depending on the size of the cable drum.

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m) The drum shall be lifted by required equipment and placed on the jacks. The cable drum
will be correctly positioned and the direction of cable pulling as indicated by arrow on
the drum shall be complied.
n) Cables will be laid / pulled by hand and / or winch. During pulling with winch, if required,
the tension on the cable will not exceed that given by the manufacturer.
o) Cables will be pulled according to drum-cable cutting schedule and as shown in the
relevant drawings.
p) Bending radius of cables shall comply with cable manufacturer’s recommendation.
q) Unless the lengths exceed the maximum drum lengths joints shall be avoided. Joint
markers indicating joint positions shall be provided above grade.
r) Before cutting the cable, both ends must be inspected to ensure sufficient length is for
proper dressing and end termination.
s) Soon after completion of every cable the cables will be tested for insulation resistance.
t) The open ends will be sealed till termination. Cable identification tags shall be installed
soon after the cable pulling.
u) Cable tags shall be installed as per Client Specification
v) The cable schedule and drum schedule will be updated with the information on cable
pulling.
w) After completion of all cables in the same route the cables shall be dressed and clamped.
x) Cable Joints position, if any, will be shown on the drawings.
y) Once the cable is laid, the processes listed out under 6.5 & 6.6 is carried out.
z) Empty cable drums will be transported back to stores.

7.2.2 Above Ground Cable Pulling

a) Cables shall be laid mainly above ground in cable trays perforated and ladder type.
b) Cable rollers shall be placed at every 6-12 meters or less if required to avoid touching of
the cable to tray.
c) Cable winch, if used, shall be positioned in proper place for cable pulling.
d) The cable drum intended for cable pulling shall be identified as per that indicated in the
drum schedule.
e) The cable drums shall be unpacked. The cable shall be fixed to the winch by means of a
cable sock or gripper.
f) Required number of persons will be posted at the winch, if used, and near the drum.
g) Cable laying will generally start from one end of the route length from other suitable
point if required.
h) In case of buildings, the drums will be placed outside the buildings and the cable pulled
in the opposite direction. After reaching the other end the length of the cable required
for reaching the location inside the building will be measured and then cut the cable.
i) In case of cable lengths which are more than one drum length, all cables which can be
laid from original position will be completed. And then the cable pulling set-up will be re-
positioned to the next location, from where the next length will be pulled.
j) Depending on the weight and size of the drum, suitable size of the cable rolling shaft
(Spindle) shall be placed inside the central axis of the drum.
k) Suitable jacks shall be placed firm ground and jacked-up to allow clearance from the
ground depending on the size of the cable drum.
l) The drum shall be lifted by required equipment and placed on the jacks.The cable drum
will be correctly positioned and the direction of cable pulling as indicated by arrow on
the drum shall be complied..
m) Cables will be laid / pulled by hand and / or winch.
n) Cables will be pulled according to drum-cable cutting schedule and as shown in the
relevant drawings.

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o) Bending radius of cables shall comply to cable manufacturers recommendation.
p) Unless the lengths exceed the maximum drum lengths joints shall be avoided.
q) Before cutting the cable, both ends must be inspected to ensure sufficient length is for
proper dressing and end termination.
r) Soon after completion of every cable the cables will be tested for insulation resistance.
s) The open ends will be sealed till termination.
t) Cable tags shall be installed as per Client Specification
u) The cable schedule and drum schedule will be updated with the information on cable
pulling.
v) After completion of all cables in the same route the cables shall be dressed and clamped.
Cables shall be fixed in horizontal or vertical runs with or Cable ties.
w) Interval of clamping will be as per Client Specification, but will not exceed 10Mtr for the
horizontal runs and 1.0Mtr for vertical runs. When single core cables are used the laying
shall be in three-foil formation (Trefoil).
x) As-Built mark-up drawings certified by Contractor’s Supervisor and Engineer will be
prepared. Cable joints position will be shown on the drawings.
y) Empty cable drums will be transported back to stores.

7.2.3 Considerations
a) Where bends are encountered in a run, cables shall be lubricated with a cable pulling
lubricant to facilitate drawing in. Petroleum based is not acceptable. During installation
process cable must not be bent to a radius of less than 12 times the overall diameter of
the cable. These conditions shall be strictly adhered to, particularly where cables turn
into road crossings, conduit entry etc.
b) Rollers must be used where cables are installed in an open trench using a pulling rope
and eye; cable rollers are to be used at frequent intervals to support the cables and must
never be more than 3 meters apart. Care must be taken to ensure that the cable does
not enter or leave the rollers at an angle that exceeds the bending radius of the cable.
The rollers are to be packed securely to prevent movement. Before driving any spikes to
secure the rollers, care must be taken to avoid other buried installations like cables etc.
below the trench floor.
c) The Pulling rope must be equipped with a swivel and be attached to the cable by a
stocking grip with pulling eye.
d) The cable shall be drawn into the trench manually, before the pull commences, to
prevent the winch to move along with the cable. The cable shall be drawn into the
trench smoothly with a minimum of stops and at an average speed of 9-12 meters per
minute, to avoid irregular movement.