RURAL WATER SUPPLY PROJECT AT

KUARMUNDA AND NUAGAON

DISTT. SUNDERGARH ODISHA

Document No.: MS-PIPING-002/Rev. A Date : 21 -09- 2020

METHOD OF STATEMENT

METHOD STATEMENT FOR LAYING, INSTALLATION,

JOINTING AND TESTING OF HDPE 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

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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
HDPE Pipes at all project in all different heights and elevations, in accordance with
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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 HDPE Pipes in the project.
This Method Statement is to ensure that HDPE 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: 4948-2016 High-density Polyethylene pipes For Water supply.

IS: 7634-2: Plastics Pipes Selection, Handling, Storage and Installation for Potable Water
Supplies - Code of Practice, Part 2: Laying and jointing of polyethylene (PE) pipes.
IS: 8008- Injection Moulded/Machined High Density Polyethylene (HDPE) Fittings for Potable
Water Supplies.
IS: 8360- Specification For Fabricated High Density Polyethylene (HDPE) Fittings For Potable
Water Supplies.
IS: 2500 part 1-Sampling Inspection Procedures.

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

Material MRS(Minimum Required Maximum Allowable Hydrostatic

Grade Strength) af Material in Design Stress (a), MPa
MPa, at 20 ‘C At 20° c At 30° c

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PE-63 6.3 5.0 4.0

PE-80 8.0 6.3 5.0
PE-100 10.0 8.0 6.3

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

7.1. MATERIALS DELIVERY, STORAGE AND HANDLING

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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. Handling and storage of straight polyethylene pipes should be such so as to avoid
penetration by sharp objects.
7.1.3. When loading, unloading or handling of large outer diameter (>160 mm), it is preferable to
use mechanical equipments. Safety precautions should be followed while unloading the
pipes at site.
7.1.4. PE pipes conforming to IS 4984, may be stored either in open or covered.
7.1.5. Polyethylene pipes shall be stored in the manner to prevent damage from elevated
temperature, contact with harmful chemicals (such as solvents).
7.1.6. The polyethylene pipes shall be stacked on a reasonably flat surface, free from sharp
objects, stones or projections likely to deform or damage them.

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.
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.
7.3.5.

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 pipeline shall be laid inside the trench with a slack of up to 2 m/100 m of pipe line.
7.4.3. HDPE piping systems jointed by butt welding, electro fusion and flanges do not require
external joint restraints or thrust block joint anchors.

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7.4.4. Polyethylene pipe requires no special bed preparation for laying the pipe underground, except
that there shall be no sharp objects around the pipe. However, while laying in rocky areas
suitable sand bedding should be provided around the pipe and compacted.
7.4.5. HDPE pipes can be used with special installation techniques such as horizontal directional
drilling, pipe bursting, micro tunneling methods of trench less technologies.
7.4.6. For HDEP pipe installation, trench width shall not be less than 150 mm from either side of
pipe. Trench depth shall be OD of pipe + (900-1100)mm or depth of cover shall be
(900-1000) mm
7.4.7. The excavated soil from the trenches should be placed such that it shall not interfere with
stringing and jointing of the pipes.

7.5. LAYING OF PIPES

7.5.1. The pipe line may be laid along side of the trench and jointed there. There after the jointed
pipeline shall be lowered into the trench carefully without causing excessive bending.
7.5.2. Polyethylene pressure piping systems jointed by butt welding, electro fusion and flanges do
not require external joint restraints or thrust block joint anchors.
7.5.3. The pipe shall be laid on a stable foundation. Where water is present or where the trench
bottom is unstable, excess water should be removed before laying the pipe.
7.5.4. Polyethylene pipes are frequently used for carrying potable water across rivers/canals/lakes.
Submerged installations require permanent concrete ballast rings attached around the pipe to
ensure that the system will stable once it is submerged. Concrete block design depends on
type of installation, tidal flows and wave actions.
7.5.5. When jointed outside of the trench the jointed pipeline shall be lowered into the trench
carefully.(preferably with mechanical handling equipment for sizes greater than 160 mm).
Due to undue bending that can cause kinking. The pipeline shall be laid inside the trench with
a slack of up to 2 m/100 m of the pipeline.
7.5.6. HDEP pipes shall not be installed near hot water pipes or near any other heat sources unless
otherwise stated by contractor.

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7.6. JOINT PREPARATION

7.6.1. The commonly used joints are as follows: a) Fusion welding: 1) Butt fusion welding 2) Socket
fusion welding; and 3) Electro fusion welding; b) Insert type joints; c) Compression
fittings/push fit joints; d) Flanged joints; and e) Spigot and socket joints.
7.6.2. Polyethylene pipes can be jointed inside or outside the trench, as per site conditions.
However, in case of jointing inside the trench, the width of the trench may be suitably
increased to ensure work space.
7.6.3. The principle of fusion welding is to heat the two pipe surfaces to a designated temperature
and then fuse them together by application of sufficient force.
7.6.4. Fusion welding of PE pipes must be carried out with welding equipment having temperature
and pressure (where applicable) display arrangements.
7.6.5. HDPE pipes and HDPE fittings, to be joined by face-to-face (butt fusion) welding must be of
the same wall thickness and the ends must be cut square. However, in some cases of fusion,
where face-to-face contact is not involved the jointing pipes/fittings wall thicknesses need not
be same.
7.6.6. The pipe ends shall be dry and free of dust. Mating surfaces shall be planed / scraped before
fusion to remove surface material as polyethylene (PE) oxidizes on exposure to air. These
prepared (scraped) surfaces should not be touched, as there is a risk of contamination of the
surface, which may affect the weld efficiency.
7.6.7. The site conditions must be protected against bad weather influences such as moisture and
temperatures below 5°C.
7.6.8. The fusion welding procedure described here is suitable for welding HDPE pipes and fittings
falling in melt flow rate (MFR) range of 0.1–1.2 g/10 min at 190°C with nominal load of 5 kgf.
7.6.9. Butt fusion equipment should be Non-stick coated heating plate with thermostat and
temperature indicator, Chamfering ( Planning) tool may be electrical / manual as appropriate,
and Electro-hydraulic power pack (for sizes greater than 125 mm) unit with pressure indicator.
7.6.10. Butt welding machines can be manual (for diameters up to 125 mm), hydraulic or pneumatic.
7.6.11. Procedure of butt fusing welding as below.
a) Clamp the pipes/fitting in the butt fusion machine.
b) Wipe the ends to be welded, inside and out, with a clean cloth to remove water, dirt, mud,
etc.
c) Welding ends should be squared. In case of pipe, plane both ends by a planer (mechanical/
electrical for pipe diameters greater than 160 mm) until they are perfectly square. Fittings’
ends can be re-cut square, where necessary
d) Remove the plastic chip from the
surrounding area of the ends without touching
the prepared surface as any contamination
will be detrimental to the welding process.
e) Bring together the two ends and ensure
they are aligned.
f) Check the hot plate (mirror) temperature
(range 200-230°C) and make certain the plate
surfaces are clean. The hot plate surface
must not be touched with hand, metal
implements or tools. A damaged or dirty hot
plate will result in a poor joint. Butt Fusion

g) Prior to heating, leveling of the pipes/fittings is essential to ensure square plane face over
the heat surface.

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h) Move the pipe/fitting ends into contact with hot plate and a steady pressure of 0.15 ± 0.01
MPa shall be applied while a uniform bead forms around the circumference of the both ends.
j) After the bead height is formed as per Table 1 relieve the pressure but maintain contact
pressure between the plate and the ends of the heated surfaces as per pressure build up time
mentioned in Table 1.
k) Push back the pipe/fitting ends away from the mirror after the above operation. When
removing the mirror, make sure it is not brushed across the molten pipe ends.
m) Bring the molten ends together and follow the recommended pressure as per the
requirement of the pipe/fitting wall thickness ( Table 1)
n) Relax the pressure and carefully remove the clamps only after ensuring that cooling time.

Table 1
Nominal Bead Height Heating Change Jointing and Cooling
Wall on the Up Over Pressure Build Cooling Time Cooling Time
Thickness Heated Tool up Time Under Pressure During Pressure
Relaxation
MM MM S S S S S
Upto-0.45 0.5 45 5 5 6 300
4.5-7 1.0 45-70 5-6 5-6 6-10 600
7-12 1.5 70-120 6-8 6-8 10-16 900
12-19 2.0 120-190 8-10 8-11 16-24 1200
19-26 2.5 190-260 10-12 11-14 24-32 1500
26-37 3.0 260-370 12-16 14-19 32-45 1800
37-50 3.5 370-500 16-20 19-25 45-60 2100
50-70 4.0 500-700 20-25 25-35 60-80 2700

7.6.12. Socket Fusion technique consists of simultaneously heating the external surface of the pipe
and the internal surface of the socket fitting until the material reaches fusion temperature
7.6.13. Procedure of Socket fusing welding as below
a) Prepare the pipe and cut at right angles and trim;
b) Chamfer pipe end. Remove burrs and chips from inside pipe ends;
c) Utilize proper depth gauge to ensure correct insertion depth and pipe roundness;
d) Clean pipe and fitting with cloth to remove all the contaminants;
e) Verify proper heater plate temperature. Temperature should be 200-230°C;

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h) Remove the pipe and fitting from

the heater. Care should be taken for
not to apply torque or twist the pipe
or fitting;
i) Quickly insert heated portion of the
pipe into the heated socket of the
fitting
j) Allow joint to cool for proper
cooling time. Be sure to maintain
pressure while cooling;

Socket fusion

7.6.14. Electro fusion is a heat fusion process where a coupling or fitting containing an integral
heating source (resistance wire) is used to join the pipes and fittings. The jointing areas, that
meets the pipe surface and the inside the fittings are overlapped.
7.6.15. During heating, fitting and pipe materials melt, expand and fuse together. Heating and cooling
cycles are automatically controlled machine.
7.6.16. Procedure of Socket fusing welding as below
a) Prepare the pipe — Cut at right angles and trim;
b) Remove the outer film of pipes using scraper;
c) Clean pipe surfaces with cleaner (as recommended by the electro fusion fittings supplier);
d) Mark the insertion depth on the pipe;
e) Remove the fittings from the
packaging without touching the fusion
surface;
f) Firmly push-in the pipe until the centre
stop or marking;
g) Mount and fix assembly attachment;
h) Slide in the second pipe up into the
fitting to centre stop or marking;
j) Firmly fasten the integrated clamp to
ensure no movement while welding;
k) Follow operating instructions of the
machine and fitting manufacturer or read
the bar code
Socket fusing

7.6.17. Other procedure may apply as per suitability and site condition such as Compression Fittings,
Compression fittings with collar/pipe ends and flat gaskets, Spigot and Socket Joint.
7.6.18.

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7.7. INSPECTION

7.7.1. 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.
7.7.2. 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.
7.7.3. Inspection records shall be properly recorded and maintained with proper identification for
each joint.
7.7.4. Inspection shall be carried out as per approved procedure and the results shall be recorded
properly.

7.8. HYDRO-TESTING

7.8.1. The pipeline to be tested shall be filled with water slowly allowing for escaping the entrapped
air. Air valves at high points should be open to allow air to escape while water is being filled.
Before pressure is applied, the pipeline section under test shall be restrained against
movement. .

7.9. BACK FILLING

7.9.1. For any size of HDPE pipe, initial backfilling 150mm should be maintained. Initial back fill
material shall be as per the standard IS: 7634 part 2. For special installation techniques such
as horizontal directional drilling, pipe bursting, no initial backfilling is required
7.9.2. In all cases, 150 mm above the top of the crown of the pipe is to be compacted either by
mechanical or manual means.
7.9.3. Care shall be taken during back filling for not to damage the pipe or joints. Filling has to be
carried out simultaneously on the both sides of the pipes so that unequal pressure does not
occur.
7.9.4. Load on the buried pipeline shall not be permitted unless the trench has been filled to the
height of at least 300 mm over the top of the pipe. Filling shall be done in layers of 150 mm,
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with the first layer watered and compacted by stamping or by mechanical means. The trench
shall be refilled so as to build up the original ground level.
7.9.5. .
7.9.6. Zone A: From the bottom of the trench to the level of the centre line of the pipe,
7.9.7. Zone B: From the level of the centre line of the pipe to a level 300 mm above the top of the
pipe,
7.9.8. Zone C: From a level 300 mm above the top of the pipe to the top of the trench.
7.9.9. 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.
7.9.10. 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.
7.9.11. 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.
7.9.12. Backfilling shall not be done in freezing weather except by permission of the authority,
7.9.13. 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.
7.9.14. 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.
7.9.15. The excavated material may be used for backfill in the following cases,
7.9.16. 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.
7.9.17. 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

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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.
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.

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