RURAL WATER SUPPLY PROJECT AT

KUARMUNDA AND NUAGAON

DISTT. SUNDERGARH ODISHA

Document No.: MS-PIPING-001/Rev. A Date : 21 -09- 2020

METHOD OF STATEMENT

METHOD STATEMENT FOR LAYING, INSTALLATION,

JOINTING AND TESTING OF DUCTILE IRON PIPES.

A 12-09-2020

Quality Manager Piping Manager Safety Manager Project Manager

Rev. Date
Reviewed By Approved By

A 12-09- Approval
2020
Rev. Date Issued for Prepared By Checked By Reviewed By
No

TABLE OF CONTENTS Page

Page 1 of 14
 RURAL WATER SUPPLY PROJECT AT
KUARMUNDA AND NUAGAON
DISTT. SUNDERGARH ODISHA

1.0 PURPOSE 3

2.0 SCOPE 3

3.0 REFERENCE DOCUMENTS 3

4.0 MATERIALS SPECIFICATION 3

5.0 DEFINITIONS 4

6.0 ROLES AND RESPONSIBILITIES 4

7.0 PROCEDURES 5

7.1. MATERIALS DELIVERY, STORAGE AND HANDLING 5

7.2. PREPARATORY WORKS 6

7.3. SITE SURVEY 6

7.4. EXCAVATION AND PREPARATION OF TRENCHES 6

7.5. STRINGING OF PIPES 7

7.6 LAYING OF PIPES 8

7.7 JOINT PREPARATION 9

7.8 INSPECTION 12

7.9 HYDRO TESTING 12

7.10 BACK FILLING 13

8.0 MANPOWER REQUIREMENTS 14

9.0 EQUIPMENT REQUIREMENTS 14

10.0 HEALTH AND SAFETY 15

1. SCOPE
The scope of this method statement is to cover laying, installation, jointing and testing of
Ductile Iron Pipes at all project in all different heights and elevations, in accordance with
Page 2 of 14
 RURAL WATER SUPPLY PROJECT AT
KUARMUNDA AND NUAGAON
DISTT. SUNDERGARH ODISHA

contract requirements, approved project specification, project safety procedure and

approved “issued for construction” drawings.

2. PURPOSE

2.1. The method statement shall address the precedence of physical operations applicable
for the laying, installation, jointing, testing and backfilling of Ductile Iron Pipes in the
project.
This Method Statement is to ensure that DI piping works activity will be executed in
an efficient and safe manner in accordance with all relevant contract documents,
(Specification and Drawings) and accepted methods. Proven methods and procedures
are to be utilized, as detailed herein and as implemented on previous projects.
2.2. This Method Statement is for submittal to Consultant/CLIENT for their concurrence.
This Method Statement will, if deemed necessary, be revised as and when required, to
accommodate circumstantial requirements that cannot be foreseen at this stage

3. REFERENCES
All materials, works and construction operations shall conform to the relevant I.S.
Specifications and standards of CPHEEO manual on Water Supply published by MoUD,
GoI. Where specifications for a work are not given, Good Industry Practice shall be
adopted to the satisfaction of the Authority’s Engineer. However, any discrepancies shall
be brought to the attention of CLIENT.

Code & Standards

IS: 12288-(R2007) Code of Practice for Use and Laying of Ductile Iron pipes.
IS: 8329: 2000 Centrifugally Cast (Spun) Ductile Iron Pressure Pipes For Water, Gas And
Sewage.
IS: 9523: 2000 Ductile Iron Fittings for Pressure Pipes for Water, Gas And Sewage
IS: 1196: 1998 Code of Practice for Laying Bitumen Mastic Flooring.
ISO: 8179 Ductile iron pipes, fittings, accessories and their joints — External zinc-based
coating
IS: 5382 Rubber Sealing Rings for Gas Mains, Water Mains and Sewers
IS: 12820: Dimensional Requirements of Rubber Gaskets for Mechanical Joints and Push-on
Joints for Use with Cast Iron Pipes and Fittings for Carrying Water, Gas and Sewage.
IS: 1200 (Part 1) Method of Measurement of Building And civil Engineering Works
CPHEEO manual -1999
Contract Documents (Schedule D, Specification and Standard)
Installation Guide for Ductile Iron Pipe – Ductile Iron Pipe Research Association (2016).
Contract Drawings No.

4. MATERIAL SPECIFICATIONS
The ductile iron materials shall meet the following requirements:

Page 3 of 14
 RURAL WATER SUPPLY PROJECT AT
KUARMUNDA AND NUAGAON
DISTT. SUNDERGARH ODISHA

Material Characteristics Pipes Centrifugally Cast Pipes not Centrifugally Cast,

Fittings, Accessories
Minimum Tensile strength (MPa) 420 420
Minimum elongation at break (%)
DN 40 to 1000 mm 10 05
DN 1100 to 2000 mm 07 05
Maximum Brinell hardness (HB) 230 250

5. TERMS AND DEFINITIONS

Client : RWSS, Rural Water Supply and Sanitation Deptt.,
Odisha

Contractor : Voltas Ltd.

Sub- Contractor : Anwesha Engineering and Projects Ltd.

CPHEEO : Central Public Health and Environmental Engineering

Organization
IS : Indian Standards
MoUD : Ministry of Urban Development

GoI : Government of India

6. ROLES AND RESPONSIBILITIES

6.1. Project Director /Project Manager: have the responsibility for overall project activities
including safety measures.
6.2. Project Engineer /Construction Manager: shall be responsible for coordination and
supervision of construction works (activities), construction groups, and all safety
measures Implementation.
6.3. Site Engineer/ Site General Foreman: shall be supervising closely the activities
designated to them ensuring that all instructions are followed and strictly adhered to.
Ensure that safety procedures of the project are strictly followed.
6.4. The QC Manager/ Engineer or his designee: The QA/QC Manager shall be responsible
for all quality related activity.
6.5. Safety Officer: is responsible for the enforcement of safety and to ensure that the works
are carried out in accordance with project safety procedures and HSE safety Plan of the
project.

7. PROCEDURES

Page 4 of 14
 RURAL WATER SUPPLY PROJECT AT
KUARMUNDA AND NUAGAON
DISTT. SUNDERGARH ODISHA

7.1. MATERIALS DELIVERY, STORAGE AND HANDLING

7.1.1. All of the materials and equipment shall be stored / preserved in accordance with the
Vendor’s / Manufacturers recommendations, requirements, technical and project
specifications.
7.1.2. During Off-Loading Cranes should be preferred for off-loading. However, for pipes up to
400 mm nominal bore, skid timbers and ropes may be used.
7.1.3. When using mechanical handling equipment, it is necessary to employ sufficient personnel
to carry out the operation efficiently with safety.
7.1.4. In case of conflict between the Vendor/Manufacturer’s recommendations and the
requirements of this document or Company documents, Vendor/Manufacturer’s
recommendations shall be adopted.
7.1.5. All equipment shipped with protective covers or plugs on openings, and with rust preventive
coatings applied on exterior machined and threaded surfaces, shall be treated as follows
on arrival at the Site:
o Protective covers, plugs shall be replaced if damaged.
o If water or dirt has entered the equipment through damaged or improperly secured
covers and plugs, the equipment shall be cleaned before covers, plugs and coatings
are put back into their former position.
o The Material Controller is responsible for inspecting the consignment for any visible
damages and quantity check to confirm the compliance with the Purchase Order (PO)
quantity (wherever applicable).

7.1.6. Pipes are to be inspected at site to see any damage to the pipe including lining or outside
coating has occurred during transportation and chandelling. Any damage (material, coating,
lining etc) in receiving material, shall be separated and informed to the concern authority
before its use.
7.1.7. Pipes being taken to a stock ground for storage and held pending further distribution should
be arranged into stacks. The first layer of pipes should be laid on a firm foundation
consisting of solid timbers set level on the ground. Subsequent layers should be placed
according to the method of stacking adopted. Care should be taken so that the pipes do not
rest on their sockets. The height of any stack should not exceed 12 ft.
7.1.8. Pipe stock may be Square Stacking, Parallel Stacking with Timbers, Nested Stacking
(Pyramid Stacking)
7.1.9. Bitumen-sheathed pipes should be handled with care to avoid any damage to the
sheathing. They should not be stacked but laid in a single layer supported on timbers
placed under the uncoated portions of the spigots and sockets.
7.1.10. Documents related to materials issue shall be maintained by the material controller till the
end of the project.

7.2. PREPARATORY WORKS

Prior to starting of work, the followings shall be checked:

7.2.1. Approval of Method Statement.

7.2.2. All the required engineering drawings and documents are approved and received in time.
7.2.3. All tools, equipment and temporary items are ready in sufficient quantities and calibrated.

Page 5 of 14
 RURAL WATER SUPPLY PROJECT AT
KUARMUNDA AND NUAGAON
DISTT. SUNDERGARH ODISHA

7.2.4. Preliminary work required to be done before laying of pipelines includes pegging out, clearing
and disposal of all shrubs, grasses, large and small bushes, trees, hedges, fences, gates,
portions of old masonry, boulders, and debris from the route.
7.2.5. Written instructions should be obtained from the Contractor/ Contractor representative for the
destruction, removal, or preservation of trees, shrubs, lawns, and fences along the pipeline.

7.3. SITE SURVEY

7.3.1. The choice of route for a pipeline is governed by economic considerations and other factors
such as overhead and underground cables, existing pipelines and traffic flow.
7.3.2. Field surveys for strip width representing about 500 m along the proposed alignments should
be carried out.
7.3.3. Any vertical section or profile along the pipeline route should be shown to a scale appropriate
to the variations in ground elevation.
7.3.4. Any Special crossings which require permission from authority should places.

7.4. EXCAVATION AND PREPARATION OF TRENCHES

7.4.1. Trenching includes all excavation which is carried out manually or by machine. The trench
shall be so dug that the pipe is laid to the required depth at required alignment.
7.4.2. The width of the trench at bottom between the faces of sheeting shall be such as to provide
not less than 200 mm clearance on either side of the pipe except where rock excavation is
involved.
7.4.3. For Cross-country laying or In Agricultural land, the depth should not less than 900 mm from
top of pipe so that the pipeline will not interfere with the cultivation of the land.
7.4.4. The depth should provide min. cover of 1100mm when laid along side or across the road.
7.4.5. Blasting for Rock Excavation shall be permitted only after the approval of the authority and
only when proper precautions are taken for the protection of persons and property. The hours
of blasting shall be fixed by the authority.
7.4.6. Open-cut trenches shall be done with the direction of contractor or governing state laws /
municipal regulations which may necessary to protect life
7.4.7. Public safety considerations, safety precautions must be observed by personnel at the job
site. The need for shoring depends on the nature of the soil and depth of the trench.
7.4.8. Care should be taken to avoid the spoil bank causing an accumulation of rainwater.
7.4.9. Suggested trench with as billow.

Page 6 of 14
 RURAL WATER SUPPLY PROJECT AT
KUARMUNDA AND NUAGAON
DISTT. SUNDERGARH ODISHA

7.5. STRINGING OF PIPES

7.5.1. Stringing consists of placing pipes on the ground in line ready for laying. Care should be taken
to prevent damage during this operation.
7.5.2. Pipe may be moved a short distance at the work site, as from one side of the street to the
other, should be rolled by hand or lifted and moved by machine. It should not be pushed or
dragged.

7.6. LAYING OF PIPES

7.6.1. Before any length of pipe is lowered into the trench, it should be inspected for damage. All
construction debris should be cleared from the inside of the pipe either before or just after a
joint is made. This is done by passing a pull-through in the pipe, or by hand, depending on the
size of the pipe.
7.6.2. Pipes should be lowered into the trench with equipment suitable for the weight of pipes. For
smaller sizes, up to 250 mm nominal bore, the pipe may be lowered by the use of ropes but
for heavier pipes, either a well designed set of shear legs or mobile crane should be used.
7.6.3. If a cable sling is used around the centre of the pipe, a wooden block placed between the pipe
and the cable will reduce the likelihood of pipe slippage.
7.6.4. On slope of 1: 15 or steeper, precautions should be taken to ensure that the spigot of the pipe
being laid does not move into or out of the socket of the laid pipe during the jointing
operations.
7.6.5. During Above Ground Laying - The ground should be dressed to match the curvature of the
pipe shell for an arch length subtending an angle of 120” at the centre of the pipes.
Alternatively, the pipeline should be laid either on saddle, roller or rocker supports as specified
by authority. The pipes may be allowed to rest on ground if the soil is non-aggressive.

Page 7 of 14
 RURAL WATER SUPPLY PROJECT AT
KUARMUNDA AND NUAGAON
DISTT. SUNDERGARH ODISHA

7.6.6. To provide a firm bed for laying of pipes, sand filling of 150mm thick shall be suggested the
trench bottom and compacted properly before laying of pipe. The sand may be river sand free
from clay and stone material.
7.6.7. Where pipes are to be bedded directly on the bottom of the trench (See Fig. IA), Where
excavation is through rocks or boulders, the pipeline should be bedded on concrete bedding
( see Fig. 1B ) or on at least 150 mm of fine grained material ( see Fig. 1C ), or other means
are used to protect the pipe and its coating.
7.6.8. When pipe are laid above ground, It is recommended that above ground installations of spigot
and socket pipes be provided with one support per pipe, the supports being positioned behind
the socket of each pipe. It is recommended normal distance between supports is 4 m. With
Flanged Pipes the recommended maximum unsupported span is 8 m. The supports shall be
located at the centre of every second pipe.

7.7. JOINT PREPARATION

7.7.1. Procedure for jointing will vary according to the type of joint being used. Basic requirements
for all types are:
7.7.2. a) Cleanliness of all parts,
7.7.3. b) Correct location of components,
7.7.4. c) Centralization of spigot within socket, and
7.7.5. d) Strict compliance with manufacturer’s jointing instructions.
7.7.6. Two main types of joints are used with ductile iron pipes and fittings: a) Socket and spigot
flexible which is divided push on joints and Mechanical joints b) Rigid flanged joint.
7.7.7. The spigot and socket flexible joint should be designed to permit angular deflection in direction
and axial movement to compensate for ground movement and thermal expansion and
contraction.
7.7.8. Both push-in and mechanical joints are flexible joints. Flexible joints require to be externally
anchored at all changes in direction such as at bends, etc, and at blank end to resist the thrust
created by internal pressure and to prevent the withdrawal of spigots.
7.7.9. Flanged joints are made on pipes having a machined flange at each end of the pipe. The seal
is usually affected by means of a flat rubber gasket compressed between two flanges by
means of bolts which also serve to connect the pipe rigidly.
7.7.10. The inside of sockets and the outside of spigots should be cleaned and wire brushed for a
distance of 150 to 225 mm. Glands and gaskets should be wiped clean and inspected for
Page 8 of 14
 RURAL WATER SUPPLY PROJECT AT
KUARMUNDA AND NUAGAON
DISTT. SUNDERGARH ODISHA

damage. When lifting gear is used to place the pipe in the trench, it should also be used to
assist in centralizing the spigot in the socket
7.7.11. Where the pipeline is likely to be subjected to movement due to temperature variations, the
use of flexible joints is recommended. A gap should be left between the end of the spigot and
the back of the socket.
7.7.12. The push-on joint consists of a special bell, plain end, and rubber gasket. The bell is provided
with an internal groove in which the appropriate gasket is seated. The plain end is bevelled,
and the joint is assembled by pushing the plain end into the bell, which compresses the
gasket and forms a watertight seal.
7.7.13. Care must be exercised that the correct gasket is being used for the joint being installed and
that the gasket faces the proper direction.
7.7.14. When pipe is cut in the field, bevel the plain end with a heavy file, an air-driven grinder, or
other suitable device and remove all sharp edges.
7.7.15. The type of cutting wheel used for cast iron pipes may not suitable for ductile iron pipe.
Special wheels, as used for cutting steel pipes, shall be used and cut ends are trimmed with a
file
7.7.16. Mechanical joints, push-on joints and gaskets shall conform to the requirements of ISO 9523.
7.7.17. In cold weather, it may be necessary to warm the gasket to facilitate insertion.
7.7.18. Push-On Joint Assembly as sequence as bellow.

(1)Thoroughly clean & Using (2) Apply lubricant to the exposed surface of
gasket of the proper design the gasket and plain end of the pipe or fitting

(3)Push the plain end into the bell socket (4) pipe can be pushed into the bell
keeping the joint straight while pushing. Socket with a long bar

7.7.19. Mechanical-Joint Assembly

Page 9 of 14
 RURAL WATER SUPPLY PROJECT AT
KUARMUNDA AND NUAGAON
DISTT. SUNDERGARH ODISHA

(1) Wipe cleans the bell recess and the (2) Insert the plain end into the socket
plain end. and press the gasket

(3) Push the gland toward the socket (4) Tighten the bolts

7.7.20. Pipeline should be securely anchored at dead ends, tees, bends, tapers and valves to resist
thrust arising from internal pressure.

Page 10 of 14
 RURAL WATER SUPPLY PROJECT AT
KUARMUNDA AND NUAGAON
DISTT. SUNDERGARH ODISHA

7.7.21. Maximum Deflection Full Length Pipe Push-on Joint may permit angular deflection to
accommodate ground movements and negotiate large radius bends. The angle deflection
shall be as per the table below:

5 ° for DN 80 to 300
3° for DN 350 to 1600

7.8. INSPECTION

7.8.1. All pipe delivered to the job site shall be clearly marked at the factory with size, type, class of
pipe, lot number, date of manufacture and manufacturers identification. Additional markings,
as required, shall also be included.
7.8.2. All pipe, and fittings shall be carefully inspected for defects immediately prior to laying. No
cracked, broken or defective materials shall be used in the work. If any defective piece shall
be discovered after having been laid, it shall be removed and replaced with a sound one in an
acceptable manner.
7.8.3. Inspection records shall be properly recorded and maintained with proper identification for
each joint.
7.8.4. Inspection shall be carried out as per approved procedure and the results shall be recorded
properly.

7.9. HYDRO-TESTING

7.9.1. The completed pipeline may be tested either in one length or in sections; the length of section
depending upon :
7.9.2. Availability of suitable water,
7.9.3. Number of joints to be inspected, and
7.9.4. Difference in elevation between one part of the pipeline and another-
7.9.5. Where the joints are left uncovered, sufficient material should be backfilled over the centre of
each pipe to prevent movement under the test pressure. The field test pressures are applied
to ductile iron pipelines only when the pipeline and its fittings are properly anchored.
7.9.6. Lengths of about 1.5 km or more, are tested in one section, subject to consideration of length
of trench which can be left open in particular circumstances.
7.9.7. Each section should be properly sealed-off, preferably with special stop ends secured by
adequate temporary anchors. The thrust on the stop ends should be calculated and the
anchors designed to resist it. All permanent anchors should be in position and, if of concrete,
should have developed adequate strength before testing begins. The section under test
should be filled with water, taking care that all the air is displaced either through vents.
7.9.8. After filling, the pipeline should be pressurized to the specified operating pressure and left for
a period of time to achieve stable conditions.
7.9.9. The pipeline is pressurized up to the full test pressure and the section under test completely
closed off. The test should be maintained for a period of not less than 10 minutes to reveal
any defects in the pipes, joints or anchorages.
7.9.10. The test pressure should be measured at the lowest point of the section under test or
alternatively, an allowance should be made for the static head between the lowest point and
the point of measurement, to ensure that the required test pressure is not exceeded at the
lowest point.

Page 11 of 14
 RURAL WATER SUPPLY PROJECT AT
KUARMUNDA AND NUAGAON
DISTT. SUNDERGARH ODISHA

7.9.11. Methods employed for finding leaks include:

7.9.12. Visual inspection of each joint if, not covered by the backfill;
7.9.13. Use of a bar probe to detect signs of water in the vicinity of joints, if backfilled;
7.9.14. Use of electronic device which detects and sound or vibrations due to escaping of water,
actual contact between the probe and the pipe is not essential;
7.9.15. Injection of a dye into the test water-particularly suitable in water-logged ground; and
Introduction of nitrous oxide in solution into the test water and using an infra-red gas
concentration indicator to detect the presence of any nitrous oxide that has escaped through
the leak.
7.9.16. If the test is not satisfactory, the fault should be found and rectified. Where there is difficulty in
locating a fault, the section under test should be sub-divided and each part tested separately.
7.9.17. After all sections have been joined together on completion of section testing; a test on the
complete pipeline should be carried out. This test should be carried out at a pressure not less
than the maximum sustained operating pressure or the maximum static pressure of the
pipeline and, during the test, inspection made of all work which has not been subject to
section tests. During the test, the pressure at the lowest point in the pipeline should not
exceed the maximum given in IS-12288-(R2007) Table 1.

7.10. BACK FILLING

7.10.1. For the purpose of backfilling, the depth of the trench shall be considered as divided into the
following three zones
7.10.2. Zone A: From the bottom of the trench to the level of the centre line of the pipe,
7.10.3. Zone B: From the level of the centre line of the pipe to a level 300 mm above the top of the
pipe,
7.10.4. Zone C: From a level 300 mm above the top of the pipe to the top of the trench.
7.10.5. Back-Fill Material shall be free from residue, ashes, slag, refuse, rubbish, vegetable or
organic material, lumpy or frozen material, boulders, rocks or stone or other material, which in
the opinion of the authority, is unsuitable or deleterious. However, material containing stones
up to 200 mm as their greatest dimension may be used in Zone C, unless specified otherwise
herein.
7.10.6. Sand used for back-fill shall be natural sand complying with fine to coarse. The total weight of
loam and clay in it shall not exceed 10 percent. All material shall pass through a sieve or
aperture size 2.00 mm and not more than 5 percent shall remain on IS Sieve or aperture size
0.63 mm.
7.10.7. Gravel used for back-fill shall be natural gravel, and having durable particles graded from fine
to coarse in a reasonably uniform combination with no boulders or stones larger than 50 mm
in size. It shall not contain excessive amount of loam and clay and not more than 15 percent
shall remain on a sieve of aperture size 75 micron.
7.10.8. Backfilling shall not be done in freezing weather except by permission of the authority,
7.10.9. Back-filling in Zone A shall be done with sand, fine gravel or other approved material placed in
layers of 150 mm and compacted by tamping.
7.10.10. Back-filling in Zone B & Zone C shall be done by hand or approved mechanical
methods in layers of 150 mm, special care being taken to avoid injuring or moving the pipe.
The type of backfill material to be used and the method of placing and consolidating shall be
prescribed by the authority.
7.10.11. The excavated material may be used for backfill in the following cases,
7.10.12. In Zone C, in cases where settlement is unimportant and when shown on the drawings
or specified, the back-fill shall be neatly rounded over the trench to a sufficient height to allow
for settlement to the required level.

Page 12 of 14
 RURAL WATER SUPPLY PROJECT AT
KUARMUNDA AND NUAGAON
DISTT. SUNDERGARH ODISHA

7.10.13. In any zone, when the type of back-fill material is not indicated or specified, provided
that such material consists of loam, clay, sand, fine gravel or other materials which are
suitable for backfilling in the opinion of the authority.

8. MANPOWER REQUIREMENTS
a. Site Engineer

b. Inspector

c. Technicians

d. Labour / Helpers

9. TOOLS & EQUIPMENT REQUIREMENTS

Personal Protective Equipment

Gum Boot

Measuring and Levelling Tools

Moveable scaffold

Ladder

Hand Tools/ Tools.

Drill Machine

Hammer

Cutter

Measuring Tape

Tool Box

10. HEALTH AND SAFETY

10.1. HSE Manager shall ensure that the work is performed accordance to the approved
Construction Safety Manual and precautions specified in the work permit. He shall ensure that
barricades, warning tapes, warning signs, fire fighting equipment and first aid kits are readily
available at the working area.
10.2. All materials, piles equipment and pipes which may serve as obstruction to traffic shall be
enclosed by fences or barricades and shall be protected by illuminating proper lights when the
visibility is poor. The rules and regulations of the local authorities
10.3. Tool box talk shall be conducted on a daily basis to inform the workers of the recent safety
issues and incidents and to get feedback of any unreported unsafe acts.

Page 13 of 14
 RURAL WATER SUPPLY PROJECT AT
KUARMUNDA AND NUAGAON
DISTT. SUNDERGARH ODISHA

10.4. The work shall be carried including closing of road/street in such a manner which will cause
the least interruption to traffic.
10.5. Area shall be barricaded adequately with warning barriers prior to any lift.
10.6. Unauthorized persons shall be excluded from the area.
10.7. Adequate caution boards and warning signs shall be provided.
10.8. On completion of job, the area shall be cleared of any materials and keep clean and tidy.
10.9. Hazard analysis for hazardous operation shall be carried out prior to commencing the works.

Page 14 of 14