SAUDI ARABIAN OIL COMPANY

NEAT KHUFF CONDENSATE FRACTIONATION PROJECT

METHOD STATEMENT
FOR
MANHOLE CONSTRUCTION

SUB CONTRACT NO: 308200

DOCUMENT NO: 308200 -MST-CI-014-Rev 02

Client : Project : Contractor : Date :

SAUDI ARAMCO NEAT KHUFF CONDENSATE DODSAL& CO. 23.01.02

FRACTIONATION PROJECT
SNAMPROGETTI

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 METHOD STATEMENT
FOR
MANHOLE CONSTRUCTION

REVISION CONTROL

Revision Date of Details of Prepared by Reviewed by Approved by Approved by

Status Issue Revision DODSAL DODSAL DODSAL SP

0 13.01.02 Initial SKJ RON AB

SP comments
1 20.01.02 SKJ RON AB
incorporated
Saudi Aramco
2 23.01.02 SKJ RON AB
Comments
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 Incorporated

METHOD STATEMENT
FOR
MANHOLE CONSTRUCTION

INDEX

1.0 PURPOSE

2.0 SCOPE

3.0 REFERENCE DOCUMENTS

4.0 DEFENITIONS

5.0 PROCEDURE

6.0 DOCUMENTATION

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1.0 PURPOSE
The purpose of Method Statement is to describe the steps to be taken for achieving
specified requirements of Manhole construction for Neat Khuff Condesate
Fractionation Project, Unit - J 64.

2.0 SCOPE

The method statement covers the required steps to be followed for Manhole
construction, coating at precast yard, lean concrete at site, lifting and transportation,
final in-situ positioning, fixing of imbedded items and precast covers, testing
requirements and back filling.

3.0 REFERENCE DOCUMENTS

Saudi Aramco Standards/Specification

Saudi Aramco Safety Manual

SCHEDULE 'Q'
09 –SAMSS- 097 :Material specification for ready mix concrete
09 –SAMSS –106 : Material specification for FBE coated bar for reinforcement
PP 276706 Rev A : Construction specification for In-Kingdom concrete.
SAES - Q- 001 : Criteria for design & construction of concrete structure.
SAES - Q- 005 : Concrete foundations
SAES - S - 070 : Installation of utility piping system.
SAES - H - 003 : Coating requirement for concrete surfaces.
SAES –M –100 : Saudi Aramco Building Codel
SAES - S- 020 : Industrial drawing and sewers
AB - 036054 : Standard drawing for Oily water sewer Manholes
AE - 036083 : Standard drawing for Manhole covers.

Snamprogetti Documents
SPC J 64 - ZA - E - 09601 Rev D: Quality plan for IK activities

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 SPC J 64 - ZA - E - 09610 Rev C: Field quality control plan for civil works
SPC J 64 - ZA - E - 09607 Rev A : General requirement for field quality control

Dodsal Procedures
DOD/NEAT KHUFF/HSE/UNS/052-Rev 1 : Project HSE Plan
DOD-QA-QC-PQP-M053-Rev 1 : Project Quality Plan
308200-MST-CI-009-Rev 1 : Method Statement for Concreting
Works
308200-ITP-CI-009-Rev1 : Inspection and Test Plan for
Concreting Works
4.0 DEFINITIONS
Oily water sewer system.
A system that removes surface run offs and effluents from process area within a
plot limit to a disposal facility, or off plot ponding area. It operates either by
gravityor pumping force. This sewer system consists of catch basins, manholes
and network of sewer piping consists of sublaterals, laterals, submains and mains.
5.0 PROCEDURE
5.1 Responsibility:
Area Engineer along with QC Inspector is responsible for all the quality-related
activities. Safety officer shall provide basic safety guidelines and it the
responsibility of area Engineer to follow.
5.2 Safety:
Basic PPE shall be used. Proper scaffolding shall be made available for working
at heights. Safe ingress and access shall be provided. Adequate lighting shall be
provided if works continue in evening/night. All basic permit system shall be
followed. Working area shall be barricated during lifting, shifting and placement
operation by crane.
5.3 EQUIPMENTS PROPOSED TO BE USED:
Concrete truck mixer
Concrete pump
Concrete vibrators
Water tanker
Excavators
Crane & trailers
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 Concrete bucket

5.4 MATERIALS
5.4.1 Concrete mix 4000psi (Type I with microsilica) shall be used from Saudi Aramco
approved Ready Mix concrete (09 - SAMSS - 097).
5.4.2 Fusion bonded Epoxy coated bar for reinforcement shall be used from Saudi
Aramco approved supplier (09 - SAMSS - 106).
5.4.3 Waterstops 250mm wide shall be used. Saudi Aramco shall approve materials
brand and type.
5.4.4 Coaltar or Bituminon Epoxy Paint confirming to APCS - 3 or APCS - 10 from Saudi
Aramco approved source shall be used (SAES - H- 101).
5.4.5 Site mixed grout (Class III) (1 part Portland cement Type I, 1 part sand and potable
water)as per PP 276706 clause 9.2.1 shall be used. The material shall be no
wetter than required for satisfactory placement. Minimum compressive strength
shall not be less than 13.8Mpa (2000psi). Fine aggregate shall confirming to
ASTM C 33 .Grout mix design to be submitted case by case and approved by SP.
5.4.6 Manhole Cover manufactured locally shall be used as per Saudi Armco Standard
S-AE-036083 Sht 1&2 ,$ 036082..

5.5 SEQUENCE OF OPERATION

Construction of manhole shall be done as below depending on site condition and
to make construction easy: -
A. Combination I : (Pre cast Raft + Pre cast Wall)

B. Combination II : (Pre cast Raft + Part Pre cast wall) + Part cast in situ wall

C. Combination III : (Pre cast only Raft ) + Full cast in situ wall

Pre cast cover shall be cast separately.

5.5.1 Construction of Manhole Raft.

Polyethylene sheet shall be placed on the pre cast bed. Suitable formwork and
rebar as per drawing shall be placed with the help of plastic spaces. Proper cover
to the reinforcement shall be provided. As per requirement lifting hooks (20mm
dia) shall be provided (if required). Waterstop shall be fixed in the raft in such a

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 way that 50% embedment should be below top raft level. Fixing and joining of
waterstops to the reinforcement shall be done as per the approved manufacture
technical data sheet.

Concreting shall be done as per the approved method statement. Sampling and
checking of concrete specimen (slump, temp) shall be done and recorded.
Concrete surface around the periphery shall be roughened for proper bonding
Curing of raft concrete shall be done for 7 days.

5.2.2 Construction of Precast wall (Part or Full)

Proper cleaning of concrete surface and rebar shall be done prior to form work.
Formwork can be started after 3 days curing of raft.
Necessary opening shall be kept in the wall as per construction drawings for
embedded spools (If required). Galvanized iron step shall be fixed in proper
position.
Lifting hook's (20mm dia - 2 nos) shall be provided in the opposite outside face of
wall. Proper anchorage shall be provided for the hook. Proper scaffolding and
working platform shall be made for easy access and keeping concrete vibrator for
concreting work..
For part precast wall construction fixing of water stopper shall be done at the
desired elevation. Any construction joint shall be water stopped.Waterstop shall be
fitted having its center in correspondance to the construction joint .
Concreting shall be done after 7 days of raft construction. Any concrete surface to
tht construction joint shall be scabbled and aggregate shall be exposed. Sampling
and checking of concrete shall be done as per the approved method statement.
Flexible hose shall be fitted to the concrete pump to minimize the free fall of
concrete.

5.5.3 Construction of Precast concrete covers

Concrete cover with lifting hooks shall be constructed as per the construction
drawings.

5.5.4 Coating of concrete at precast yard or in-situ

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 After 7 days casting of concrete, suitability of concrete surface shall be checked for
coating visually. Suitability of concrete surface shall be judged with the plastic
sheet method as per ASTM D 4263 (SAES - H - 003).

Repair (if any) shall be done prior to concrete coating with cement sand mortar
(grout type III, as per PP 276706) or approved concrete repair material (as per
manufactures technical data sheet).

5.5.5 Lean concrete for Manhole : Top level of concrete shall be maintained as per
construction drawing.

5.5.6 Lifting & Transportation of Manhole

Lifting and transportation of precast portion (Combination I, II & III) shall be done
minimum after the completion of curing that will be about 7 days of curing period
but not less than 70% of the required strength of concrete.

5.5.7 Final In-situ Positioning.

Final position (Line, level) shall be maintained for all manholes as per the drawing.

5.5.8 Casting of Wall (In-situ)

Depending on site condition and constraints part or full wall shall be cast at site as
per combination II & II. Concreting shall be done as per approved method
statement. Coating shall be done as per paragraph 5.5.4.

5.5.9 Fixing of Embedded Spools.

Embedded spools shall be fixed in position as per relevant construction drawing
and isometrics. Opening in the wall shall be kept properly (if required). Scrabbling
and soaking of opening shall be done prior to grouting (site mix grout type III).
Curing of grout shall be done for 3 days ( Clause 9.3.2.E of PP – 276706 Rev A ).
Coating of grout portion shall be done as per clause 5.5.4.

5.5.10 Testing of Manholes

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 After fully installation of manhole/piping system, testing shall be conducted. A
separate method statement shall be prepared (if required).

5.5.11 Fixing of Precast Cover.

Concrete cover shall be fixed at required level over the wall. Cement grout (site
mixed grout class III) shall be used for this purpose.

5.5.12 Backfilling around Manholes.

Backfilling around manholes shall be carried out as per the approved method
statement. Layer thickness and compaction control shall be recorded. Below
water table, excavated sand shall be used for filling. Therefore due to
cohessionless property of sand, it will be compacted automatically. No compaction
test shall be required below water table.

6.0 DOCUMENTATION
Site concrete Register: Details for pouring and curing.
Form no. MDT.CV.CDQ.9 Sht. 01 Rev. 1.95 : Report for Hydrostatic test of Manhole and
Basins.
Forn no. MDT.CV.CDQ.10 Sht 01 Rev. 1/95 : Report for sewer system pipes Hydrostatic
Test.
Form no. MDT.CV.CDQ.3 Sht 01 : Report for check after structural concrete
placement.
Form no. NDT.CV.CDQ.5 Sht 01 : Daily concrete pour record.
Form no. NDT.CV.CDQ.20 Sht 20 : Inspection report of formation level status
before lean concrete pouring.
Format No. DOD/NEAT KHUFF/ F005 Rev 0 : checklist for concrete coating.
Format No. DOD/NEAT KHUFF/F004 Rev 0 : Foundation Survey Report

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