Professional Documents
Culture Documents
DUCTWORK
(The content of this method statement is subject to material submittal approval)
2.0 OBJECTIVES 4
3.0 REFERENCES 4
8.0 RESPONSIBILITIES 20
9.0 ENGINEERING 20
10.0 MATERIALS 21
13.0 ENVIRONMENT 22
1.1. To define the methodology to be followed during the fabrication of HVAC ductwork and
installation of fabricated ductwork and its associated accessories in supply, return,
exhaust, and fresh air ducts and all such inline components as indicated on the approved
shop drawings.
1.2. To ensure, the installation and testing are in compliance with the specifications,
standards and project specific requirements.
1.3. This procedure is applicable to all HVAC ductwork installation and activities which include
components such as, AHU, and FCU connections, flexible ducts, sleeves, identification,
supports, etc.
2. OBJECTIVES
2.1. To ensure the work is carried out as per approved planning sequence of work and project
schedule with adequate resources to meet target.
2.2. To ensure the construction of the scope of work is in accordance with project
specifications, SMACNA, and approved shop/coordination drawings.
3. REFERENCE DOCUMENTS
4. GENERAL
4.1. Prior to the procurement of any materials and equipment all such materials and
equipment shall be submitted to the client for approval. Only approved materials may be
used in the fabrication and installation of the ductwork systems. Ducts shall be
constructed of material of the correct wall thickness, correct reinforcements, with joints
and seams as per the classification applicable to each system.
4.2. Ductwork shall be constructed of galvanized steel sheet, except where specifically stated
otherwise or as indicated on the approved shop drawings.
4.3. Rectangular or square ductwork shall be prime locked forming quality:
4.3.1. Galvanize sheet steel to comply with ASTM A653/653M
4.3.2. Metal gauges in accordance with published SMACNA HVAC Duct Construction
Standard – Metal and Flexible to suit the duct configuration and classification.
4.3.3. Carbon steel sheet to comply with ASTM A 1008A/1008M
5. PRE-WORKS
This product must be evenly applied to the coated surfaces. Even and uniform
application is essential for satisfactory results. The procedures, equipment and
techniques described below have been used to provide the desired result.
Other procedures, equipment and techniques may also achieve satisfactory
results, but must not be used without discussing the specific situation with a
qualified professional for assistance.
The applicator must have access to the surfaces being coated. This will require
entering the ducts. In such cases, application must start from the point most
distant from the point of entry into the duct. The applicator will then work from
that point back to the entry point covering a 4 foot length of duct at a time.
5.14.6. Using Brush or Roller: Brushes and paint rollers suitable for application of water
based paints are acceptable. Use a 3/8” nap roller for smooth surfaces. Clean
brushes and equipment with warm water before product dries.
5.14.7. Rate of Application: The required rate of application for Foster Fungicidal
Protective Coating varies depending on the surface being coated. Users of this
product must carefully follow the rate of application instructions provided
above. Surfaces must be evenly coated to provide a complete surface film.
Avoid over application resulting in pooling of the coating.
6. WORKS
6.1. Duct sections shall be transported from the workshop to the work site in applicable
manner.
6.2. Ensure that scaffolding is executed in high areas and safety check tag is properly
displayed.
6.3. Inline equipment such as dampers, fire dampers, VAV boxes, etc. shall be stored in a
suitable storage facility on site, as required. Supporting systems such as threaded rods,
angle iron, etc. shall similarly be stored in suitable storage facilities as will sealants and
other assembly components.
6.4. Using approved for construction shop drawings the duct routes shall be marked on the
underside of the slab or otherwise as per the dimensioned location as shown on the
drawings.
6.5. Confirmation shall be received from the consultant that the areas where the ductwork is
to be installed, have been released for such works to proceed.
6.6. Supports shall be installed as per the approved support and hanger details. Supports shall
be securely installed and adequate for the purpose. Supports shall be spaced in
compliance with the approved support and hanger details.
6.7. Vertical supports shall be installed as per the approved support and hanger details and as
per SMACNA standards. Supports shall be securely installed and adequate for the
purpose. Refer to below image for reference.
Method Statement for HVAC DUCTWORK & ACCESSORIES
Page 7 of 20
6.8. As indicated on relevant approved construction drawings where more than one duct can
be supported on one hanger the size of the hanger will be accessed on the sum of the
maximum widths.
6.9. All support materials such as anchors, threaded rod, angle iron, etc. shall be of approved
materials in compliance with the specifications or approved alternative.
6.10. Round duct sections and flexible duct shall be supported by means of a suitably approved
type of support as per the approved support and hanger details.
6.11. Duct sections shall be lifted in to place either manually or mechanically, depending on
the weight, size and elevation of the ducts final position. Once located as shown on the
drawings the supports shall be finalized and the section secured in position either by
connection to the previously installed duct sections or by temporary suitable restraints or
supports.
Method Statement for HVAC DUCTWORK & ACCESSORIES
Page 8 of 20
6.12. Ensure that insulation shall not be damaged during lifting and insulation is properly done
at the joint.
6.13. Each successive section of duct shall be joined to the previous piece, taking care to
ensure that the joints are correctly sealed with the approved duct sealant or gasket
material.
6.14. Duct sections shall be joined together by means of flanges or as per the specifications
and SMACNA standards. Transvers joints using S-clip, C-clip drive etc. shall be sealed by
means of approved duct sealant.
6.15. Where duct sections are to be joined by means of welding at joints, project specification
and SMACNA standards to be adhered to strictly.
6.16. Allowance or branch or spur lines shall be made at the fabrication stage in compliance
with the specifications and standards.
6.17. Duct risers shall be installed through the building openings provided. Ducts shall be
placed in the openings as per the dimensioned locations as shown on the drawings.
Ducts rising through shafts shall be installed in a similar manner, where necessary a
coordinated drawing section will be provided and details shall be checked to confirm the
exact location of ducts. Duct riser supports shall be as per approved shop drawing detail.
6.18. At no time shall ductwork locations vary from that shown on the approved for
construction shop drawings, without first seeking approval from the engineering
department.
6.19. Approved re-routing of ducts shall be “Red Lined” on the appropriate drawings and
forwarded to the engineering department for the As-Built drawings, for final hand over.
6.20. All left out openings around the ducts shall be sealed off with the approved sealing
materials.
6.21. During installation the open ends of ducts and accessories shall be protected to prevent
dirt or debris from entering.
6.22. For all non-fire rated penetrations where no fire dampers are to be installed a sleeve of
the same gauge as the duct is to be installed at the opening to prevent the duct and it’s
insulation from the opening.
6.23. Pre-fabricated plenum boxes shall be installed as shown on the IFC drawings. Plenum
boxes shall be installed and secured as per the specifications and standards.
6.24. Variable Air Volume (VAV) boxes shall be located and installed per the approved for
construction shop drawings. VAV boxes shall be supported by means of a suitably
approved type of support as per the approved support and hanger details.
6.25. Volume control dampers (VCD) and back draft dampers (BDD) and all other inline
accessories shall be located and installed as per the approved for construction shop
drawings and in compliance with project specifications. Ensure VCD and BDD can freely
move through its full rotation.
6.26. In line equipment is to be independently supported.
6.27. Fire dampers and smoke dampers shall be installed as per the locations indicated on the
approved for construction shop drawings and using the approved installation detail
method statement for the same. Ensure the correct type and size of damper is installed
in each location by referring to the fire and smoke damper schedule.
6.28. Ensure all attenuators/duct silencers are of approved material and construction.
Attenuators shall be located and installed in the locations indicated on the approved for
Ductwork testing shall be carried out in compliance with the project specifications and
SMACNA - HVAC Air Duct Leakage Test Manual.
7.1. Precautions:
7.1.1. Prior to commencing any ductwork pressure testing it will be necessary for all
such ductwork to be inspected. The direct line construction supervisor shall first
inspect the installation to ensure compliance with the specifications. On
satisfactory inspection and making good and defects, the QA/QC department
will be requested to inspect the works.
7.1.2. All open end ductwork shall be properly capped during testing.
7.1.3. All open ends will be checked to ensure they are sealed.
7.1.4. Verify that an adequate and matched electric power source is available for the
test apparatus.
7.1.5. Determine that the capacity of the test apparatus is suitable for the amount of
duct to be tested.
7.1.6. Isolate equipment (fans, in-line flanged coils, volume regulating boxes, etc.)
from tested ductwork. The system designer should have independently
accounted for leakage in equipment.
7.1.7. Anticipate difficulty with any test of ductwork that has no prescription for
sealing yet is required to meet an allowable leakage level.
7.1.8. Do not over pressurize ducts. Provide pressure control or pressure relief if test
apparatus behavior is unfamiliar; e.g., start test apparatus with flow restricted
and gradually build up pressure.
7.1.9. Prepare carefully when testing in cold weather. Low temperature influences the
effectiveness of sealants and gaskets.
Leakage classification identifies a permissible leakage rate in cfm per 100 ft2 of duct
surface according to the relationship CL = F ÷ (P) 0.65.
P0.65 P″ 3 6 12 24 48
1 1 3 6 12 24 48
P0.65 P″ 3 6 12 24 48
P0.65 P″ 3 6 12 24 48
7.19. All testing must be done by means of an appropriately sized blower, which shall be
connected to the section of duct to be tested. See figure below for illustration of the
setup.
9. ENGINEERING
9.1. Ensure that the shop drawings issued to site are approved and latest.
9.2. Shop drawings shall follow the IFC drawings, project specification requirements and local
authority’s codes and regulations.
10. MATERIALS
10.1. All materials shall be submitted for approval prior to procurement and delivery to site.
10.2. Materials shall be inspected on delivery site, to ensure compliance with the approved
submittal. An Over, Shortage, and Damage report shall be completed for all deliveries.
10.3. Materials shall be unloaded in a proper manner, by manual or as necessary mechanical
means (by crane or forklift). Materials shall not be dropped to the ground, but lowered
carefully.
10.4. All related documents, such as delivery notes, country of origin, bill of landing, test
certificates, etc., shall be available along with materials when delivered to site.
10.5. Materials will then be reconciled with the mill certificates, where applicable and any
uncertified/non-compliant materials will be removed into quarantine.
10.6. Material shall be stored appropriately or placed on shelving units within the warehouse
area.
10.7. Care shall be taken to prevent the ingress of dirt or foreign objects into materials.
10.8. Items requiring preservation and maintenance shall be subject to the requirements of
the Preservation and Preventative Maintenance Procedure.
10.9. Manufacturer’s instructions with regard to storage requirements shall for the basis for
material storage and preservation.
11.1. All equipment/tools shall be inspected prior to use at site and Mercury MENA ID tag shall
be placed on equipment where applicable.
11.2. No modified tools may be used for any task.
11.3. All test equipment shall be checked to assure that they are in good condition and valid
calibration certificates are maintained and available for review.
11.4. Operator’s documentation shall be verified as applicable.
11.5. Tools that will be used for the headlined scope of works are as follow but not limited to:
11.5.1. Measuring tape, plumb bob, chalk line, nylon string line
11.5.2. Ball peen hammer
11.5.3. Ladder
11.5.4. Spirit level
11.5.5. Duct fitter standard tool box
11.5.6. Screw driver set
11.5.7. Rivets/Screws
11.5.8. Square drive rachet spanner
11.5.9. Box spanner
11.5.10. Allen socket adaptor
11.5.11. Calibrated torque wrenches
11.5.12. Electric impact screw driver
11.5.13. Blower fan for leak testing
11.5.14. Anemometer/Monometer
11.5.15. Flow meter
11.5.16. Scaffolding
11.5.17. Drill machine
11.5.18. Grinding machine
11.5.19. Sheet cutters
12.1. All safety rules & regulation for the project shall be adhered to at all times. Third party
certified equipment’s and competent personnel to be deployed. Required permit to be
secured. Risk assessment and risk control measures are to be in place.
12.2. All site personnel shall be properly equipped with protective clothing and tools
appropriate for their duties and shall ensure that work area facilities are safe prior to the
commencement of work activities.
12.3. All individual tasks mentioned in this method statement will be subject to individual, risk
assessments and toolbox talks by safety officer on site before work commences on a
daily basis.
12.4. No refuelling whilst equipment is running. Refuelling to be carried out only at designated
areas on site.
12.5. Provide banks man or spotter during equipment manoeuvring and during hauling of
excavated materials.
12.6. All lifting tackle will be inspected before use.
13. ENVIRONMENT
13.1. Works will proceed under controlled environment. Control measures identified in the risk
assessment to be in place. Significant aspect highlighted to dust and contamination
during dewatering. Dust suppression by means of water sprinkling and dewatering
method statement to be followed.
14.1. After approval of this Method Statement, a pre-construction meeting to be held among
the supervisory staff involved. Trainings mentioned in the risk assessment to be followed.
15.1. Significant stages of work shall be monitored and ensured to be enforced by the
concerned as per the Inspection and Test Plan (ITP) attached to this document.
Inspection request to be submitted to the Engineer a day prior to inspection schedule.
15.2. Quality Control tests on performed work and materials shall be in accordance with
Project Specification
16. ATTACHMENTS
16.1. ITP
16.2. HSE Risk Assessment
2.0 OBJECTIVES 4
9.0 ENVIRONMENT 14
1.1. To define the methodology to be followed for the installation of duct insulation and the
inspection of the installed insulation.
1.2. To establish the acceptable criteria for the storage, handling, and application of such
insulation.
1.3. To establish the acceptance criteria for the installed insulation. This method shall be
verified to Manufacturer’s Method of Insulation Application which is submitted and
approved by the supervision consultant.
1.4. This method statement is applicable to the application of insulation to all ducting
systems as set out in the project specifications and the approved shop drawings. The
insulation of in line equipment, is also covered by this method statement.
2. OBJECTIVES
2.1. To ensure the work is carried out as per approved planning sequence of work and project
schedule with adequate resources to meet target.
2.2. To ensure the construction of the scope of work is in accordance with project
specifications, SMACNA, and approved shop/coordination drawings.
3. REFERENCE DOCUMENTS
4. CONSTRUCTION METHODOLOGY
4.1.1. Ensure all drawings are the latest revision and approved for construction issue.
4.1.2. Check the location of structural openings in relation to ducting routes as
indicated on the drawings to ensure adequate room for insulation.
4.1.3. Check the location of the ducting within risers to ensure adequate space has
been allowed to facilitate the application of insulation.
4.1.4. Confirm that adequate means of access to high level insulation area is available.
Check all scaffolds and mobile towers are in compliance with the project
requirements.
4.1.5. Check to ensure that all equipment and tools required, to undertake the works in
a proper and efficient manner, are available and in good working order.
4.1.6. Ensure that all quick assembly mobile towers are assembled correctly.
4.1.7. Ensure that all personnel assembling and dismantling such towers are
adequately instructed on correct assembly methods.
Method Statement for HVAC DUCTWORK & ACCESSORIES
Page 3 of 11
4.1.8. Prior to commencing any works, a risk assessment must be conducted, taking in
to account all possible risks and the appropriate precautions put in place, i.e. fire
extinguishers, fire blankets, safety harnesses, etc. Refer to the risk
assessment/risk management section of this method statement.
4.2.1. All works shall be undertaken in a neat and workmanlike manner to ensure a
quality inspection.
4.2.2. Check the insulation material size and thickness is correct and as per
specification.
4.2.3. Access to duct routes at high level beneath the slab shall be by scaffolding or
mobile tower scaffolding. Such mobile towers shall be constructed as per
manufacturer’s instructions, with proper bracing and guard rails as required. No
tower may be moved with personnel on the structure of the tower.
4.2.4. Weld pins will not be used to secure the insulation as they break the integrity of
the galvanized coating, which in the course of time will lead to a corrosion point.
4.2.5. Visually inspect the duct surface to ensure it is clean, with no dust, oil/grease, or
other chemicals are left on the pipes to be insulated.
4.2.6. Work in a clean area and avoid dusty places.
4.2.7. To clean the substrate surface, first wipe down with a clean cloth to remove
excess dust. Then remove grease and oil using a suitable cleaning agent. Wipe
ducts clean and allow cleaning agent to evaporate.
4.2.8. Conventional hangers are suitable for the installation of Thermo break. If the
duct is insulated before it is installed, the hanger base must be lined to protect
Thermo break against compression (Figure 1). A strip of Thermo break cut to size
would be suitable.
Figure 1
Table 1
Figure 2
Figure 3
4.2.10.8. Repeat until completely covered. On the final side, ensure the insulation
length reaches the same level as the starting edge. Trim off excess length
with sharp knife until it is level with adjacent side. (Figure 4)
Figure 4
4.2.11. Joints:
4.2.11.1. Joints should be butted firmly together. The factory cut straight edge
allows perfect mating between two sections.
4.2.11.2. Ensure no gaps are visible. In case of gaps, trim the edge again in a straight
line to ensure proper alignment of butt joints.
4.2.11.3. In cases where the edges do not align perfectly, a 50mm width strip of
Thermobreak can also be used to cover any visible gaps.
4.2.11.4. Seal all joints with aluminium foil tape as per Taping Instructions (Section
4.2.13)
4.2.12. Flanges:
4.2.12.1. Insulation should be butted against flange joints tightly.
4.2.12.2. For flange insulation use 150-200mm wide insulation strip.
4.2.12.3. Fix one side first with aluminium foil tape, and then fold material over
flange and fix with aluminium foil tape (Figure 9 and Figure 10). A small
gap in the corner is normal and does not affect the performance of the
insulation.
Figure 6
Figure 7 Figure 8
4.2.14.7. Fix tape over all joins, ensuring a continuous seal. Where possible, the
length of the tape should not only exceed the length of the join, but
continue around the next edge to provide an anchor point. There should
be at least 50mm overlap.
5. RESPONSIBILITIES
6.1. All equipment/tools shall be inspected prior to use at site and Mercury MENA ID tag shall
be placed on equipment where applicable.
6.2. No modified tools may be used for any task.
6.3. Tools that will be used for the headlined scope of works are as follow but not limited to:
6.3.1. Measuring tape
6.3.2. Ladder
6.3.3. Scaffoling
6.3.4. Duct Insulator Standard Toolbox
6.3.5. Knife/Cutter
6.3.6. Plain Plate – for pressing insulation
7. MATERIAL HANDLING
7.1. All materials shall be manufactured by one of the approved manufacturers or otherwise
approved.
7.2. All materials shall be submitted for approval prior to procurement and delivery to site.
7.3. Materials shall be inspected on delivery site, to ensure compliance with the approved
submittal. An Over, Shortage, and Damage report shall be completed for all deliveries.
7.4. Insulation and ancillary material shall be unloaded in a proper manner, by manual or as
necessary mechanical means (by crane or forklift). Materials shall not be dropped to the
ground, but lowered carefully.
7.5. Material shall be stored appropriately to prevent damage. Material shall not be placed
directly on the ground.
7.6. All related documents, such as delivery notes, country of origin, bill of landing, test
certificates, etc., shall be available along with materials when delivered to site.
7.7. Material shall be stored appropriately or placed on shelving units within the warehouse
area.
7.8. Care shall be taken to prevent the ingress of dirt or foreign objects into materials.
7.9. Items requiring preservation and maintenance shall be subject to the requirements of
the Preservation and Preventative Maintenance Procedure.
8.1. All safety rules & regulation for the project shall be adhered to at all times. Third party
certified equipment’s and competent personnel to be deployed. Required permit to be
secured. Risk assessment and risk control measures are to be in place.
8.2. All site personnel shall be properly equipped with protective clothing and tools
appropriate for their duties and shall ensure that work area facilities are safe prior to the
commencement of work activities.
8.3. All individual tasks mentioned in this method statement will be subject to individual, risk
assessments and toolbox talks by safety officer on site before work commences on a
daily basis.
8.4. No refuelling whilst equipment is running. Refuelling to be carried out only at designated
areas on site.
8.5. Provide banks man or spotter during equipment manoeuvring and during hauling of
excavated materials.
8.6. All lifting tackle will be inspected before use.
8.7. All personnel will have undergone the applicable safety training and wear PPE i.e., Safety
Helmet, Steel-Toed safety Boots or Shoes, Safety Glasses and coveralls as the minimum
requirement and gloves and High Vests where necessary.
8.8. For dusty working environment dust masks shall be used.
9. ENVIRONMENT
9.1. Works will proceed under controlled environment. Control measures identified in the risk
assessment to be in place. Significant aspect highlighted to dust and contamination
during dewatering. Dust suppression by means of water sprinkling and dewatering
method statement to be followed.
10.1. After approval of this Method Statement, a pre-construction meeting to be held among
the supervisory staff involved. Trainings mentioned in the risk assessment to be followed.
11.1. Significant stages of work shall be monitored and ensured to be enforced by the
concerned as per the Inspection and Test Plan (ITP) attached to this document.
Inspection request to be submitted to the Engineer a day prior to inspection schedule.
11.2. Quality Control tests on performed work and materials shall be in accordance with
Project Specificatio
2.0 Objectives 4
3.0 References 5
4.0 General 5
7.0 Responsibility 17
8.0 Engineering 17
13.0 Environment 21
This Method Statement covers all related Chilled water piping (Above/Ground) system
installations activities which include:
a) Chilled water piping(Supply/Return)
b) Valves,Fittings,Accessories
c) Pressure Testing
d) Identifications
e) Sleeves
2. OBJECTIVES
This document provides a method statement for chilled water piping (Above/Ground)
system in accordance with the Contract Scope of work.
The work will be carried out as per approved planning sequence of work and project
schedule with adequate resources to meet target.
The work shall consist of Chilled water piping (Above/Ground) system along with
accessories about the installation procedure with respect to Project specifications, QCS-
2010, Approved shop drawing and the manufacturer recommendations.
3. REFERENCE DOCUMENTS
3.1 Project Specifications Sec.(15075,15184)
3.2 Tender/ Contract documents.
3.3 Project IFC Drawings.
3.4 Approved Shop Drawing
3.5 Project Quality Plan.
3.6 HSE Plan.
3.7 QCS-2010 References section-22.
Method Statement for the Installation of
Chilled water Piping System
Page 3 of 17
4. GENERAL
a) Ensure that the Chilled water pipes, fittings, valves and accessories are correct
and as per project specification and approved material submittal before
commencing the installation works.
b) Prior to commencing any works, a risk assessment must be conducted, taking
into account all possible risks and the appropriate precautions put in place, i.e.
fire extinguishers, fire blankets, safety harnesses, etc. Refer to the risk
assessment/risk management section of this method statement.
c) Ensure that shop drawing used on site are approved and latest prior to
commencing works on site.
5. PRE WORKS
6. WORKS
6.1 Chilled water piping installation shall be as per Interpipe (manufacturers) recomm
endations
6.2 Chilled water piping & fittings should be correctly used as per approved material s
ubmittal.
6.3 Install piping to allow adequate service space for equipment.
6.4 Install piping free of sags or bends.
6.5 Diagonal runs are not permitted, unless expressly indicated on the drawings.
6.6 Horizontal run random lengths of pipe may be lifted into place using mechanical m
eans or manual means, depending on the size of the pipe.
6.7 All pipes will be supported by hangers / supports at intervals as approved / recom
mended by the manufacturer/supplier and contract specifications, Confirmed the in
stallation of support hanger, bracket is securely fixed and at the correct elevation.
6.8 Allow sufficient thread on threaded rods for pipe level adjustment. Upon satisfactor
y levelling cut back excess threaded rods and touch up with approved paints.
6.9 Install drains throughout systems to ensure that the entire system can be drained.
This includes but is not limited to all low points, bases of all risers, and at each bra
nch take off.
6.18 Eccentric reducer fittings should be used in horizontal positions and concentric r
educer fittings for vertical installations.
6.19 Welding of pipe in situation shall be minimized by the pre-fabrication of spools at
ground level, or in the fabrication facility on site. Spools will be fabricated in manag
eable lengths, making allowance for the field weld location.
6.20 Site sketches will be prepared for all spools by the relevant engineer or supervis
or.
6.21 Pipes shall be marked and cut square and cleanly by cutting disc or Oxy/Acetyle
ne cutting torch as applicable.
6.22 Pipe ends will be prepared according to the type of joint, i.e. threaded, butt weld.
Pipe ends for welded joints will be prepared by grinding as per the approved weldi
ng procedure.
6.23 On completion of pipe end preparation check to ensure the inside of the pipe is f
ree of all dust and debris.
6.24 Where pipes penetrate through walls and floors sleeves of the appropriate size a
nd type, according to the wall or floor type, shall be installed.
6.25 Pipes going through sleeved shall be independently supported of the sleeve as p
er an approved support detail. All vibration isolators shall be installed as per appro
ved shop drawings.
6.26 Pipes going through risers shall be supported from the building structure as per a
n approved support details.
6.27 Proper clean out, Tees with dummy caps and drain valve should be installed as p
Method Statement for the Installation of
Chilled water Piping System
Page 6 of 17
er site requirements.
6.28 Proper safety precautions should be taken for pipe installation in Shaft/risers with
proper lifting tools.
6.29 Branch connections shall be made using standard fittings of the appropriate wall
thickness or “Weld-o-lets”.
6.30 All high points shall have vents installed and all low points shall have drain point
s installed as indicated on the approved drawings or as identified on site.
6.31 All valves shall be installed as indicated on the approved drawings & Crane (ma
nufacturers) recommendations. Valve orientation and flow direction shall be carefu
lly checked. And it should be in positions of maintenance.
B. SETTING – UP OF EQUIPMENTS
a) Place visible signage i.e. “System Under Pressure”, “Keep Away”, “Danger
”, “Caution”
b) Warning notices and barricades (if deemed necessary) will be used to identify t
he system under test.
D. REPAIR OF LEAKS
a) During initial filling, employ sufficient man power to monitor the entire length of
piping system for possible leakages.
b) If leakages are observed, arrest the leakages immediately. If leakages are maj
or, isolate the leaking portion with nearest isolating valve and / or stop the wate
r filling.
c) Rectify the leakages and again fill the water.
d) Examine clearly the source of noted leak. If the leak is coming from joints/fitting
s, drain the pipeline and check the joints/fittings of each pipe. Also check the fit
ting for any scratch or internal surface damage. Replaced the fitting if necessar
y.
e) In some cases, leaks come from a pipe end plug. Drain the pipeline and unscre
w the plug. Examine closely its threaded, if damage, replace such plug.
f) Physically inspect the entire circuit for any leaks. If any leaks are detected then
they are to be attended prior to proceeding further.
g) Leaks and repairs (if any) will be repaired as necessary and pipe work will be r
etested.
h) Repeat the leak test procedure after clearing the leaks (if any).
i) Consultant shall be notified in advance, as per agreed procedures and/or contr
act requirements, to witness the test by issuing an inspection request.
a) Site Engineer shall ascertain that the pipeline under test is leak proof while coo
rdinating with QC for the consultant site inspection and/or witnessing the test.
b) QC engineer shall inform the consultant for the testing being conducted. The c
onsultant shall, on his discretion, witness the whole testing process up to satisf
ying the design and specification requirements.
c) All tests result shall be recorded in the format as per approved QC procedure /
documentation.
a) Provide a safe and adequate disposal of test water after successful water pres
sure test.
Make sure that test water disposal is carried out without damaging
any finished item, and to ascertain that it will not cause any
untoward incident
c. QA/QC Engineer shall ensure that all works are carried out strictly in
accordance with approved method statement, and Inspection and test plan.
d. Safety Engineer, Safety Officer, Safety Assistant shall ensure that works
are carried out in accordance to approved method statement, Risk
assessment and control measures.
9. ENGINEERING
a. Ensure that the shop drawings issued to site are approved and latest.
b. Shop drawings shall follow the IFC drawings, project specification requirements
and local authorities’ codes and regulations.
10. MATERIALS
a. In this method statement following materials shall be used:
Chilled water pipes & fittings (pipes & fittings).
Valves, strainer, air vent and accessories.
Support (Threaded rod, clamps, nuts/bolts, jutes, tefflon tapes etc).
Identifications.
Sleeves (penetration).
b. Material will be delivered at site in undamaged condition, in manufacturer’s pac
kaging, with identifying labels intact and legible.
c. All related documents i.e. delivery notes, country of origin, bill of landing and te
st certificates shall be available along with materials.
d. Materials will be off loaded according to manufacturer’s recommendations.
e. Pipes or fittings will not be drop or drag.
f. Pipes and fittings will be offloaded in our lay down area prior to transport to site
.
g. The storage area must be flat. The ground must not be marshy or unstable and
it must not contain any corrosive material.
Method Statement for the Installation of
Chilled water Piping System
Page 13 of 17
h. Timber supports of suitable size shall be placed at equal distance below the Ch
illed water pipes.
i. Pipes shall be stacked on a flat surface free from any sharp objects and shall b
e given adequate supports at all times.
j. While stacking it shall be ensured that pipes of bigger sizes will be placed at th
e bottom and smaller sizes at the top.
a. All safety rules & regulation for the project shall be adhered to at all times.
Third party certified equipment’s and competent personnel to be deployed.
Required permit to be secured. Risk assessment and risk control measures are
to be in place.
b. All site personnel shall be properly equipped with protective clothing and tools
appropriate for their duties and shall ensure that work area facilities are safe
prior to the commencement of work activities.
c. All individual tasks mentioned in this method statement will be subject to
individual, risk assessments and toolbox talks by safety officer in situ before
work commence on a daily basis.
d. No refuelling whilst equipment is running. To be done only at designated area
on the field.
e. Provide banks man or spotter during equipment manuvering and during hauling
of excavated materials.
f. All lifting tackle will be inspected before use.
g. All personnel will have undergone the applicable safety training and wear PPE
i.e., Safety Helmet, Steel-Toed Safety Boots or Shoes, Safety Glasses and
coveralls as the minimum requirement and gloves and High Vests where
necessary.
Method Statement for the Installation of
Chilled water Piping System
Page 15 of 17
h. For dusty working environment dust masks shall be used.
13. ENVIRONMENT
Works will proceed under controlled environment. Control measures identified
in the risk assessment to be in place. Significant aspect highlighted to dust and
contamination during dewatering. Dust suppression by means of water
sprinkling and dewatering method statement to be followed.
16. ATTACHMENTS
ITP
Pressure Test Report
HSE Risk Assessment
2.0 Objectives 4
3.0 References 4
4.0 General 5
8.0 Engineering 41
12.0 Environment 43
This Method Statement covers all related insulation for chilled water piping system
activities which include:
a) Insulation for Chilled water pipe works, Fittings, Valves and accessories.
2. OBJECTIVES
This document provides a method statement for insulation of Chilled water piping system
in accordance with the Contract Scope of work.
The work will be carried out as per approved planning sequence of work and project
schedule with adequate resources to meet target.
The work shall consist of Insulation for Chilled water piping system along with
accessories about the installation procedure with respect to project specifications,
approved shop drawing and the manufacturer recommendations.
3. REFERENCE DOCUMENTS
3.1 Project Specifications Sec.(15081)
3.2 Tender/ Contract documents.
3.3 Project IFC Drawings.
3.4 Approved Shop Drawing
3.5 Project Quality Plan.
3.6 HSE Plan.
3.7 QCS-2010 References
a) Ensure that the insulation for Chilled water pipes, fittings, valves and accessories are
correct and as per project specification and approved material submittal before
commencing the installation works.
b) Prior to commencing any works, a risk assessment must be conducted, taking into
account all possible risks and the appropriate precautions put in place, i.e. Fire
Extinguishers, Fire Blankets, Safety Harnesses, etc. Refer to the risk assessment/risk
management section of this method statement.
c) Ensure that shop drawing used on site are approved and latest prior to commencing
works on site.
5. PRE WORKS
a) Installation procedure shall be as per manufacturer’s recommendations.
b) All workers shall attend safety induction training on the safe installation methods by th
e safety department.
c) Ensure that chilled water insulation materials received are inspected; found acceptabl
e as per approved materials submittal.
d) Ensure that all related materials are of approved make and are available before carryi
ng out any work.
e) Prior to commencement of work, inspect areas and access to confirm that the site is r
eady for commencing the work.
f) Material shall be stored appropriately and stacked on wooden blocks and placed on le
vel ground in the lay-down area.
g) Material shall be stored appropriately to prevent damage. Material shall not place dire
ctly on the ground.
h) Manufacturer’s instructions with regard to storage requirements shall form the basis fo
r material storage and preservation.
i) Chilled water insulation shall be protected from direct sunlight and foreign debris and
stored as per Manufacturer’s recommendation.
j) All relevant documentation (drawings) and materials applicable to particular section of
works will be checked by site engineer prior to commencement of work and ensure th
at shop drawings are as of latest revision approved.
k) MEP site engineer/ site supervisor will give necessary instructions to tradesmen (Pipe
Insulator) and provide necessary construction shop drawings of latest revision.
l) MEP site supervisor/ foremen will also check that proper insulation tools like cutter/Kn
ife and other equipment are available to carry out the work and are in compliance with
manufacturer’s recommendations and safety policy.
m) MEP site supervisor and safety officer will explain to the tradesmen regarding safety p
recautions to be observed.
6.2 Chilled water insulation shall be as per approved Material Submittal, Shop drawings,
Project specifications
6.3 All works shall be undertaken in a neat and workman ship manner to ensure the qualit
y of insulation installation.
6.4 Ensure that the insulation size, thickness and other aspects are as per approved mate
rial submittals.
6.5 Insulation material will be installed over clean, dry pipe at ground level without coverin
g joints.
6.6 Insulation should be protected from moisture and weather before applications as per
manufacturer’s recommendations.
6.7 All Insulation section shall be trimmed and tight to avoid gaps or open joints. The insu
lation application shall be fitted and proper tightness should be ensured.
6.8 The joints will be insulated after the installation and pressure testing of pipes. All joints
should be insulated properly to avoid condensation and follow manufacturer’s recomm
endations for joining.
6.9 The tapes/Glue around the ends/joints of pipe shall be as per manufacturer’s recomm
endations.
6.10 Insulation for valves/strainers & other accessories shall be carried out with more pre
caution, ensure that the surface is free from dust, water or grease particles.
6.11 Insulation shall be measured and cut as required.
6.12 Identifications/Labels for Chilled water pipe works as follows:
a. Identifications Labels for Chilled water pipe works services
should be as per Approved Material submittal/Shop Drawi
ngs, Project Specifications and Manufacturers recommend
ations.
b. Identifications labels shall with stand climatic conditions. T
he Size, Font and Colours should be as per Approved Mat
erial Submittal, Project Specifications and Manufacturers r
ecommendations.
c. Chilled water (Supply/Return) should have their own identi
fications with flow direction marked on the label.
d. The insulated surface where the label is going to be place
d should be cleaned to ensure it is free from dust.
e. The identification label is of self-adhesive type and it shoul
d be installed on the cleaned surface indicating the correct
direction of flow.
7. RESPONSIBILITY
All personnel engaged in the Insulation of Chilled water piping System activity
shall be of adequate experience in their respective discipline
b) Site Engineer, Surveyor and Foreman is responsible for the installation activities in
accordance with the scope of work, approved drawings, related specification and HSE
requirements implementation.
c) QA/QC Engineer shall ensure that all works are carried out strictly in accordance
with approved method statement, and Inspection and Test plan.
d) Safety Engineer, Safety Officer, Safety Assistant shall ensure that works are
carried out in accordance to approved method statement, risk assessment and
control measures.
8. ENGINEERING
a) Ensure that the Shop Drawings issued to site are approved and latest.
b) Shop drawings shall follow the IFC drawings, Project Specification requirements and
Local Authorities Codes and regulations.
9. MATERIALS
a) The following material shall be used for chilled water pipe insulation:
I. Insulation sheet or tube
II. Tape/Glue for joining.
b) Material will be delivered at site in undamaged condition, in Manufacturer’s packaging
, with identifying labels intact and legible.
c) All related documents i.e. delivery notes, country of origin, bill of landing and test certi
ficates shall be available along with materials.
d) Materials will be off loaded according to manufacturer’s recommendations.
e) Chilled water insulation will be offloaded in our lay down area prior to transport to site.
f) Delivery of Chilled water insulation will be checked / Inspected by MEP QC engineer t
o ensure all items on the delivery note are correct prior to signing. Any shortage or da
maged items should be recorded on the delivery note and damage Materials will store
separate with identification tag or shall be removed from site.
g) Upon delivery of materials at contractor’s site stores, inspection will be offered for Con
sultant approval.
a) All safety rules & regulation for the project shall be adhered to at all times. Third
Party certified equipment’s and competent personnel to be deployed. Required
Permit to be secured. Risk assessment and risk control measures are to be in place.
b) All site personnel shall be properly equipped with protective clothing and tools
appropriate for their duties and shall ensure that work area facilities are safe prior to
The commencement of work activities.
c) All individual tasks mentioned in this method statement will be subject to individual,
risk assessments and toolbox talks by safety officer in site before work commence
on a daily basis.
d) No refuelling whilst equipment is running. To be done only at designated area on the
field.
e) Provide banks man or spotter during equipment manuvering and during hauling of
excavated materials.
f) All lifting tackle will be inspected before use.
g) All personnel will have to undergo the applicable safety training and wear PPE i.e.,
Safety Helmet, Steel-Toed safety Boots or Shoes, Safety Glasses and coveralls as
The minimum requirement and gloves and High Vests where necessary.
h) For dusty working environment dust masks shall be used.
12. ENVIRONMENT
Works will proceed under controlled environment. Control measures identified in the
risk assessment to be in place. Significant aspect highlighted to dust and
contamination during dewatering. Dust suppression by means of water sprinkling
and dewatering method statement to be followed.