METHOD STATEMENT

INSTALLATION OF HDPE PIPES & FITTINGS

Project Name:
Design, Construction, Completion and Maintenance of Court at Madinat Zayed, AL Dhafra Region.
Method Statement Title:
Installation of HDPE pipes and fittings
Client: Method Statement Reference No:
MZC-00SIT-AL-NIM-MEC-MST-0024-00-Rev.00
MUSANADA

TABLE OF CONTENTS

1- Purpose:
2- Scope:
3- Legislation and code of practice:
4- References:
5- Definitions:
6- Resources:
6.1 Materials and their approval
6.2 Subcontractor approval
6.3 Shop drawings approval
6.4 Equipment
6.5 Human Resource
7- Safety Precautions/ Risk Assessment:
8- Detailed Construction Sequence (Methodology)
9- Inspection and Testing Plan ( ITP ):
10- Related Forms:
11- Attachments:
 METHOD STATEMENT
INSTALLATION OF HDPE PIPES & FITTINGS

1.0. PURPOSE:

The purpose of this method statement is to define the procedures to be adopted, to assure that the
laying of the pipe line and associated works are carried out strictly in accordance with the requirement
specified in the relevant specification, procedures, manufacturer’s recommendation and relevant
drawings.

This procedure describes the methods to be used for the installation of HDPE Pipes, fittings and
associated works on this project.

2.0. SCOPE:

This Scope of Works shall be read in conjunction with the Drawings, Standard Specifications and
Particular Specifications if mentioned. The scope of this method statement & Quality plan shall cover the
following activity:

 Survey and Setting out work

 Excavation to required formation level
 Installation of HDPE pipe & fittings
 Pipe bedding and surround
 Backfilling
 Testing
 Laying of detectable warning tape
 Locating & protecting existing services
 Preparation of Existing ground level
 Filling of the area with approved material
 Other applicable works as per approved shop drawings
 HSE, Traffic and Environmental Management Plans for Segment Construction
 Recording of all filling detail.

3.0. LEGISLATION AND CODE OF PRACTICE:

The legislation and code of practice to be followed as per approved HSE plan of the Project.
 ASTM & ISO standards for pipes
 Abu Dhabi Environment, Health and Safety Management System (ADEHSMS)
 CoP 2.0-PPE
 CoP 3.0-Occupational Noise
 CoP 4.0-First Aid & Medical Emergency Management
 CoP 6.0-Emergency Management
 CoP 7.0-Fire Prevention Planning
 CoP 11.0-Safety in heat
 CoP 14.0-Manual Handling and Ergonomics
 CoP 17.0-Safety signage and Singles
 CoP 21.0-Permit to work
 CoP 22.0-Barricades of Hazards
 CoP 27.0-Confined space
 CoP 29.0-Excavation
 CoP 33.0-Working in, over or adjacent to road.
 METHOD STATEMENT
INSTALLATION OF HDPE PIPES & FITTINGS

 CoP 34.0-Safe use of Lifting Equipment and Accessories

 CoP 36.0-Plant and equipment
 CoP 39.0-Overhead and underground services.
 CoP 44.0-Traffic Management.
 CoP 53- EHS Management during Construction
 CoP 54- Waste Management
 All UAE Environmental Regulation.

4.0. REFERENCES:
The following documents should also be read in conjunction with this method statement.

 Project specification Civil Spec. 219.7 , Drawings & Manufacturers procedures.

 ADM - SECTION VI-1 Materials and Materials for Fire Fighting works.
 ADM - SECTION VI-2 Fire Fighting system - Underground
 ADM - SECTION VI-3 Pipe laying, jointing and inspecting
 ADM - SECTION VI-4 Construction of Fire Fighting pipe installation and other related
works.
 ADM - SECTION VI-5 – Completion of Fire Fighting pipe work.
 Method statement for Surveying/ setting out
 Method statement for excavation & backfilling
 Method statement for Dewatering
 Section- Installation testing of HDPE Pipes & Fittings
 Method statement for water proofing
 Method statement for Concreting Cast in situ.

5.0. DEFINITION

ADM - Abu Dhabi Municipality

WRM - Western Region Municipality
Client - Judicial Department
Employer - Musanada
Engineer - RW Armstrong & associates l.l.c.
CCG - Consolidated consultants Group
NIGM - National innovative general maintenance l.l.c.
MS - Method statement
FFS - Fire Fighting system
HIRA - Hazard identification & Risk assessment
INSP - Inspector
PM - Project Manager
SE - Site Engineer
SS - Site Supervisor
TS - Technical Specification
RFI - Request for Inspection
SO - Safety Officer

6.0. RESOURCES :

6.1: Material

 Only Approved Materials shall be used during the construction of Fire fighting system.
 Any material changes encountered or should a change in a source of material be made
shall be submitted for Engineer approval before the construction stage.
 METHOD STATEMENT
INSTALLATION OF HDPE PIPES & FITTINGS

 Following materials to be used.

 HDPE pipes & Fittings (of the required types, sizes etc. in the contract)
 Approved pipe bedding and surround material
 Dune sand
 Approved Backfilling material
 Detectable warning tape
 Concrete grade C20 as blinding, pipe bed and surround
 Grade C20 precast concrete blocks
 Approved Backfilling material

6.2: Sub Contractor Approval

Not applicable.

6.3: Shop drawings approval

All shop drawing of the construction activity shall be approved

6.4 Equipment

 Fusion welding equipment

 Electrical generators, fusion coupler
 Clamps, Jointing Tackles, trimmers & heater plate
 Spanners, Torque wrench
 Cutting machine
 Rollers
 Survey Equipment
 Ladder
 Slings/Ropes
 Pipe fitter Tools
 Fittings Slings
 Barricade/Plastic barriers
 Hydraulic Excavators,
 Rock Breaker (when required),
 Jointing Tackles,
 Water Tankers,
 Dewatering Systems,
 Testing instruments & Equipment’s such as pumps, gauges, stop ends etc.

6.5: Human Resources

 Site Engineer / Project Engineer.

 Foreman/Supervisor
 Pipe fitter, fixer
 Welder
 HSE officer
 Labour
 Mason
 Bank man/Signaller

7.0. Safety Precautions/ Risk Assessment:

 METHOD STATEMENT
INSTALLATION OF HDPE PIPES & FITTINGS

Please refer the detailed methodology of HSE requirements and risk identified in Risk
Assessment sheet

7.0.1 Emergency Service Telephone: 056-9666234

7.0.2 Emergency Service Telephone:

Fire Service/Civil Defence 997

Hospital 998
Police 999

7.0.3 Personnel Protective Equipment

 Safety Jackets
 Safety shoes
 Helmet
 Hand Gloves
 Safety Goggles
 Ear plug

7.0.4 Site Equipment

 Safety cones or barriers

 Sign Boards
 First Aid Kit
 Fire Extinguisher

7.0.5 Emergency Arrangement

 Emergency Procedure shall be brief to all personnel

 Contact numbers for the emergency service shall be provided by the site safety
office and held by the foreman
 First aider and first aid kits shall also be assigned in different areas of the
project
 Presence of fire extinguisher in designated areas.
 Emergency contact no. were posted in strategic areas within the project
 All workers involved in activity shall strictly follow the emergency procedure.

7.0.6 HSE traffic and Environmental Management plan

The Health, Safety and environmental Management Plan for the project has been
prepared to meet the various HSE & Traffic and Environmental management
requirements as mentioned in Contract Document and also as per the established
HSE & Traffic and Environmental Management System and Procedure of M/s
NIGM

Environment

 M/s. NIGM will have overall responsibility of Environment

 All new workers and staff will attend environment induction courses before
inducted in site
 Typical Environment management measures shall be monitored according to
Project Construction Environment management plan.
 Good Housekeeping,
 Refer to Construction Environment management plan for detailed compliance in
regards with
 METHOD STATEMENT
INSTALLATION OF HDPE PIPES & FITTINGS

o Noise control
o Air quality
o Control of Exhaust emission
o Control of dust emission
o Soil ground water quality
o Weekly and monthly environmental inspection shall be
conducted
General Safety

 Project HSE Plan

 Safety Hazards and Precautions
 All personnel involved will be equipped with the necessary personal protection
Equipment including Hard hats, Safety Boots, Safety Glasses, overalls, Gloves/
and Harnesses.
 All personnel will attend and complete site awareness and safety induction.
 All personnel will have read and understood the relevant method statement and
instructions.
 A tool box talk will be part of all operatives' induction prior to commence of
each phase.
 All permits to work systems will be adhered to including Manhole excavation,
trench/Pit man Entry permits
 Visitors shall be accompanied by person in possession of a valid safety induction
identity card.
 Safety precautions shall be implemented to control hazards and prevent
incidents to the public.
 Operations adjacent to public accesses and through fares to the public shall be
reviewed and monitored by the Safety Officer throughout the duration of the
works.

Induction

 All workers and staff shall attend the HSE induction before commencing the
work at site
 All personnel shall adhere the PPE
 All work shall attend tool box talk held weekly
 Any unsafe act or condition are to be identified and corrected immediately and
referred to respective supervisor
 Any accident or incident shall be reported immediately to take preventive
measures

Training

 All will be briefed with approve MS & HIRA

 Daily briefing shall be conducted prior to start activity
 Tool box talk will be given to operatives.

8.0 DETAILED CONSTRUCTION SEQUENCE (METHODOLOGY)

8.0.1 Mobilization of Plant/Equipment and Manpower:

Mobilization of Plant/Equipment/Machinery and Manpower shall be as per

finalized and approved construction schedule / Programs.

8.0.2 Survey and Setting out Works:

 METHOD STATEMENT
INSTALLATION OF HDPE PIPES & FITTINGS

After completion of the preliminary original ground level by GPS system the
area shall be marked in grid system. Before commencing this work all underground and
existing services and obstruction are clearly marked and dealt with approved method
statement

 Surveyor shall ensure that all survey equipment is calibrated and having valid
calibration certificate and he shall also ensure that the pipe laying is done to the
require line and level.
 Survey check Report / Other relevant data shall be recorded
 Original ground level for the whole construction site will be surveyed and
recorded, After the completion of the daily joint survey, the data collected will be
printed in hard copies for joint signature, Work shall only be commenced in area
surveyed where survey sheet are jointly signed. After establishing full survey
record, plan will be prepared and submitted for approval.
 Work location shall be designated well ahead according to Programme to enable
achieving the planned production.
 Existing services shall be located by use of cable detectors and trial excavation;
they shall be clearly marked at site.

8.0.3 CONSTRUCTION PROCEDURES:

8.0.3A Preliminary

 One set of relevant approved shop drawings, sketches etc. indicating the setting out
details, levels etc. shall be made available at the site of work for verifying &
inspection prior to commencement of pipe laying. All the existing utilities to be
confirmed and marked by using trial pits excavation.
 Verify the survey points established as per previous approved method statement and
to ensure that all reference points are found intact without any damage or removed.
 Ensure that trench formation is dry and free from obstructions, depressions, debris,
loose soil, stones etc. Dewatering if required shall meet the requirements.
 Ensure that formation is compacted to the true line, level and gradient as per
specification.
 WIR shall be submitted in the approved format 24 hours prior to inspection of any
activity, and be approved by the consultant.
 Mobilize the required materials, plant, equipment and manpower as required to
ensure a prompt start & completion of work as per project schedule.
 All materials shall be inspected (MIR) prior to use for installation and any damaged
material shall be identified and stored separately.

8.0.3B Pipe Handling Pipe.

 Care shall be taken not to damage the pipe when handling. Pipes shall not be stored
on rough or rocky ground. Pipes shall be placed without timber blocking on pipe
barrels. Pipes has to be inspected and any damage has to be recorded and notified.
Damaged goods shall be marked and removed from site. Pipes shall be handled and
stored as per manufacturers recommendations.

8.0.3C Cutting pipe

 Pipe shall be cut using milling type cutter, rolling pipe cutter or abrasive cutter. Do
not use flame cut.
 METHOD STATEMENT
INSTALLATION OF HDPE PIPES & FITTINGS

8.0.3D Pipe Trench

 Generally the width of the trench should be the minimum dimension compatible
with safe working and the satisfactory laying, jointing and bedding of the pipe.
 The cover height of all pipes shall not be less than 1200 mm measured from top of
the pipe to the finished grade level or as shown in the approved drawing.
 Where trenches are required to be deeper than the general depth mentioned the
trench shall be dug to a required depth with a gradual slope necessary for proper
laying of the pipeline.
 Pipe line shall not be closer than 300mm to the other pipeline services or structures.
 The trench width depends on the nature of ground, depth and pipe size. The clear
width of the trench at any level shall be min of one pipe diameter plus 300mm (±
50mm).
 In all cases trench shall be excavated sufficiently to ensure efficient laying and
jointing of pipes.

8.0.3E Pipe bedding and surround material

 Pipe bedding and surround material for HDPE Pipes shall be as per specification.
 All bedding & surround material shall be subjected to prior approval of the engineer.
 Pipe surround material shall be wetted and lightly tamped or compacted in place.

8.0.3F Pipe laying

 All pipes shall be installed in trenches at variable depth below surface depending on
the architectural, shop drawing and road details
 Pipes crossing the streets shall be well protected and embedded in sand.
 All pipes fitting valves etc shall be carefully lowered into the trench with suitable
equipment in a manner that will prevent damage.
 Open ends of the pipe shall be closed whenever pipe laying is not in progress and at
the end of the day to prevent entry of any foreign matter.
 Install all items in accordance with recommendation of the manufacturer, installing
each item firmly in position, level, plump and properly connected.
 Special foundations or other fixing supports/ blocks shall be provided as required
 Care shall be taken to ensure pipeline is clear and free of all foreign matter at all
times. Sufficient backfill shall be placed on the pipe to prevent floatation. Any pipe
that has floated shall be removed from the trench and re-laid in a dry trench.
 As the installation of the various system components are completed, they shall be
adequately cleaned before final closing. All foreign materials shall be removed from
equipment and surrounding areas.

8.0.3G Pipe jointing - BUTT FUSION

 HDPE Pipes and fittings can be assembled into a pipeline network by means of Butt
Fusion with same SDR & pipes & fittings of the same nominal diameter.
 Butt fusion machine consists of machine body, hydraulic unit, heater and milling
cutter.
 Butt fusion is thermo-fusion process which involves the simultaneous heating of the
ends of two pipe/fitting components which are to be jointed, until a molten state is
attained on each contact surface. The two surfaces are then brought together under
controlled pressure for a specific cooling time and a homogenous fusion joint is
formed.
 An electrical heater plate is used to raise the temperature of the pipe ends, ends are
finished and made suitable for joining by using milling cutter.
 The main requirements to be fulfilled are hydraulic tightness as well as structural
stability of the system.
 The resultant joint is fully resistant to end loads and has comparable performance
under pressure to the pipe itself.
 METHOD STATEMENT
INSTALLATION OF HDPE PIPES & FITTINGS

 HDPE pipes can be flange jointed by using HDPE stub flange ends in conjunction
with backing plates and a sealing gasket to provide a demountable joint or to
matchup with pumps, valves etc.
 Automatic welding equipment must be used which provides complete data storage
and data retrieval to record all conditions used for each weld.
 Suitable electrical generator along with voltage regulator acceptable to the Client
engineer shall be used.
 The welder performing the Fusion weld shall be subject to annual welder
qualification tests.
 Fusion welding equipment selected shall ensure cycle is automatically controlled,
Pipe cannot be released from the machine or clamps until the specified cooling time
has elapsed, All critical parameters in the process are recorded.
 Welding shall be performed as per the Client approved welding method statement.
HDPE pipe Manufacturer shall submit the welding method statement along with the
technical submittal which will be reviewed and submitted to client for approval prior
to its implementation at site.
 To ensure high quality welds are produced, the welds shall be numbered to ensure
traceability, only certified welder shall be performed fusion welding. Certificates
shall be submitted for engineer’s approval.
 Weld inspection & Testing shall be performed as per section

8.0.3H Testing

 HDPE Piping Hydro-testing Procedures:

 Proper backfilling should be provided to the testing pipe & keep the Joints open for
inspection.
 It is necessary to fill, pressurize and test the section within the allotted time for the
test.
 One end of the test section to be closed with the End cap or blind flange and the
other end of the test section to be connected with the testing flange having water
inlet connected to the calibrated pressure gauge & air out let.
 Fill the test section slowly with water and ensure that no air is trapped in the test
section.
 Air release valve to be connected to the system at the highest point to expel the
trapped air and to get the system completely filled with water.
 During pressure testing, gradually increase the pressure in the test section to the
required test pressure.
 Add make up water as necessary to maintain maximum test pressure.
 Monitor the test section at test pressure for the test duration.
 As per ISO standard, pressure test can be conducted 1.5 times the rated pressure for
2 hours at 20°C.

8.0.3I Construction of Appurtenances

 As the pipeline installation progresses, thrust blocks, valves, valve chambers, wash
out chambers, etc, will be constructed in accordance with the approved for
construction drawings.

8.0.3J Construction of Piping within the pump house and valve rooms

 The piping will be installed using flanged joints in accordance with the Approved
shop drawings and shall be hydrostatically tested to the specified pressure.
 The flange gasket shall be centrally located and the flange bolts shall be properly
tightened in accordance with the manufacturers and the mechanical requirements.
 A torque wrench should be used securing the needed compression. Proper supports
 METHOD STATEMENT
INSTALLATION OF HDPE PIPES & FITTINGS

shall be installed in accordance with the drawings giving importance to its elevation
and location. Torque shall be as per manufacturer’s recommendation if applicable.

9.0 Inspection and test plan:

Attached Inspection and test plan No.:

10.0 Related Forms:

MIR – Material Inspection Request

WIR – Work Inspection Request

 Attachments:

 Appendix A: Inspection and Test Plan.

 Appendix B: Checklist