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METHOD STATEMENT FOR INSTALLATION OF HVAC

DUCTWORK
(The content of this method statement is subject to material submittal approval)

Method Statement for HVAC DUCTWORK & ACCESSORIES


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TABLE OF CONTENTS

Section Description Page No

1.0 PURPOSE AND SCOPE 4

2.0 OBJECTIVES 4

3.0 REFERENCES 4

4.0 GENERAL 4-6

5.0 PRE-WORKS 6-9

6.0 WORKS 9-12

7.0 DUCT AIR LEAKAGE TEST PROCEDURE 13-19

8.0 RESPONSIBILITIES 20

9.0 ENGINEERING 20

10.0 MATERIALS 21

11.0 PLANT AND EQUIPMENT 21-22

12.0 HEALTH, SAFETY & WELFARE 22

13.0 ENVIRONMENT 22

14.0 COMMUNICATION AND TRAINING 23

15.0 QUALITY CONTROL 23

Method Statement for HVAC DUCTWORK & ACCESSORIES


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1. PURPOSE AND SCOPE

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

3.1. Project Specifications (Section 15075, 15812, 15820)


3.2. Project IFC Drawings
3.3. SMACNA – HVAC Duct Construction Standards 2nd Edition 1995
3.4. Approved Shop Drawings (as applicable)
3.5. Approved Material Submittal (as applicable)
3.6. Project Quality Plan
3.7. Project HSE Plan

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

Method Statement for HVAC DUCTWORK & ACCESSORIES


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4.3.4. Stainless steel sheet to comply with ASTM A480/A480M – Type 304 or 316 as
indicated on drawings. Exposed surface finish to be No. 4 finish and concealed
surface finish to be No. 2D
4.3.5. Aluminum sheets to comply with ASTM B 209 Alloy 3003, H14 temper. With mill
finish for concealed ducts, and standard, one-sided bright finish for duct surfaces
exposed to view.
4.4. Round ductwork shall be prime lock forming quality:
4.4.1. Galvanize sheet steel to ASTM A653/653M
4.4.2. Metal gauges in accordance with published SMACNA Round Industrial Duct
Construction Standards to suit the duct configuration and classifications.
4.5. Seismic restraints shall be installed in compliance with the specifications and as indicated
on the approved shop drawings.
4.6. All angle iron required for ductwork construction or supports shall be galvanized.
4.7. Rectangular duct joinery and fabrication shall be as specified in the specifications and in
compliance with SMACNA.
4.8. Rectangular duct fittings shall be as specified in the specifications section, and in
compliance with SMACNA.
4.9. Round and oval joinery and fabrication shall be as specified in the project specifications,
and in compliance with SMACNA.
4.10. All unlined duct shall be cross broken or beaded in accordance with SMANCA.
4.11. All unlined duct shall be coated with anti-microbial/fungicide coating in accordance with
the manufacturer recommended procedure.
4.12. Ensure approved for construction shop drawings of current revision are available prior to
fabrication and installation commencement.
4.13. All ductwork shall be coordinated with other services to ensure access to execute the
works.
4.14. Construction and installation of the HVAC ductwork systems shall be as per approved
shop drawings.
4.15. It will be necessary to give consideration to the sequence in which the work shall
proceed.
4.16. Prior to commencing any works, 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 harness, etc. Refer to the risk assessment/management section of this
method statement.

5. PRE-WORKS

5.1. Ductwork shall be pre-fabricated in an off-site facility by a prequalified and approved


sheet metal fabricator.
5.2. The fabrication shall be carried out in a neat and workmanlike manner, with all internal
and external surfaces free from projections and sharp edges.
5.3. The ductwork fabricator shall prepare duct manufacturing drawings from the approved
shop drawings, showing detailed dimensions for the different composite parts, such as
elbows, branches, off-sets, straight runs, etc.
5.4. Where flanges are utilized, they shall be of approved manufacture and fitted in
accordance with SMACNA.

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5.5. Duct reinforcement shall be in compliance with SMACNA standards. Where sealing is
applied at the fabrication stage or the installation stage, it shall be as per the approved
duct sealant.
5.6. Ductwork sections shall be fabricated from approved materials and in compliance with
the project specifications and SMACNA. Duct sections shall be fabricated with approved
joints and seams. Ducts shall be adequately braced to prevent vibration.
5.7. Duct sections shall be fabricated in manageable lengths. The site supervisor and the
fabrication supervisor shall review all duct runs to establish that fabrication sequence,
best suited for ease of installation.
5.8. Acoustically lined ductwork shall be fabricated in accordance with the SMACNA standard
and located as shown on the IFC drawings. Dimensions for acoustically lined ducts are
clear inside dimensions.
5.9. Fabricated sections shall be labelled, giving the following information:
- Gauge Number
- Dimensions
- Line Number
- Location
- Type of duct (supply/return/exhaust/fresh air)
5.10. Fabricated sections shall, on arrival to site, be monitored by the QA/QC department to
ensure compliance with the specifications.
5.11. All ductwork shall be checked when delivered to site, for correct dimensional accuracy,
based on the factory fabrication shop drawing and the labelled affixed to it.
5.12. On delivery to site duct sections shall be inspected to ensure that they are not damaged.
Sections will be stored in a suitable environment prior to insulations and anti-microbial
coating is applied. Ductwork shall be stored as such to avoid it coming in contact with
abrasive surfaces. Delivery shall be coordinated to ensure ductwork is delivered to
coincide with the installation schedule, and thus limit the storage requirements on site.
5.13. Duct sections are to be thoroughly cleaned of any debris and dust and placed in the
insulation section of the duct workshop on site. Duct to be insulated as per approved
method statement (submitted separately).
5.14. Ducts that are insulated and are clean on the inside surface to be coated with a
microbial/fungicide coating. The coating application on to ducts is to be as per the
manufacturer recommended procedures. Following is the procedure for the approved
material:

5.14.1. Anti-microbial Coating Material: Foster 40-25


5.14.2. Surface Preparation: Apply only to surfaces free of all loose dirt, grease, mould
or other materials that may interfere with the adhesion of the coating to the
substrate. Remove any dust, grease, oil, or materials. Abrade all surfaces to
remove all surface rust. Clean the intended surface of any materials that may
interfere with the adhesion of the coating and allow to dry completely before
proceeding. Follow manufacturer’s directions for application. All rusted metal
surfaces must be primed before application of Foster Fungicidal Protective
Method Statement for HVAC DUCTWORK & ACCESSORIES
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Coating. Foster Fungicidal Protective Coating may be applied directly onto
cleaned un-rusted galvanized surfaces.
5.14.3. Material Preparation: DO NOT THIN. Keep container closed.
5.14.4. Product Application: Apply between 50ºF (10ºC) and 100ºF (38ºC) with less
than 70% RH air conditions maintained until dry. Always ensure adequate
ventilation. Workshop must be under negative air pressure during and after
application to allow for exhausting of odours and rapid drying of the coating.
Apply Foster Fungicidal Protective Coatings to all surfaces by brush or airless
spray at the following wet coverage rates (rates are minimum required and are
subject to the nature of the material being coated):
- Galvanized Metal = 0.75 gal/100 ft2 (0.31 L/m2)
- New Duct Liner = 1.0 gal/100 ft2 (0.41 L/m2)
Unsealed, rough, or low density surfaces may require more material to attain
required surface sealing.
Continue to circulate fresh dry air throughout the area during the application
and for as long after the application as is possible. This circulation and filtration
helps to reduce the dry time of the coating and reduce latex type odours that
could possibly migrate from the application area.
5.14.5. Application Techniques: Foster Fungicidal Protective Coating may be applied by
brush, roller or airless spray as well as certain automated spray systems. Refer
to sections below for more information on application equipment and devices.
Brushing or rolling will require two coats applied at 90º to each other. Under
normal circumstances a spray application can be completed in one coat, but for
extremely porous or irregular surfaces, a second coat may be required. Overlap
applications to assure complete coverage and the surface is smooth and well-
sealed. Cover surface completely while avoiding runs or pooling.

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.

Method Statement for HVAC DUCTWORK & ACCESSORIES


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5.14.8. Maintenance: Normal cleaning procedures must be maintained in HVAC
systems to remove accumulated airborne particles. Where accessible the
coating may be washed down periodically to remove any accumulation of
materials with water and a mild detergent. If coating becomes damaged clean
surface and re-apply coating.
5.15. After completion of the coating process and proper drying of the same, the open ends of
the ducts to be sealed with durable plastic sheeting to prevent the ingress of sand, dirt,
water, or other contaminants.

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
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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
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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

Method Statement for HVAC DUCTWORK & ACCESSORIES


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construction shop drawings. Attenuators shall be supported by means of a suitably
approved type of support as per the approved support and hanger details.
6.29. Access doors shall be provided at all fire dampers, smoke dampers, automatic control
dampers, filters, etc. and all other apparatus concealed within the duct as shown on the
approved for construction shop drawings and in compliance with the project
specifications. Access doors shall also be installed in straight runs, before or after turning
vanes, etc. as per project specifications to ease in access during cleaning of ducting.
Access doors shall be of the pressure classification and construction standards as
designated by the designers and shall be of size as specified in the project specifications.
6.30. Flexible ducts shall be connected from branch duct to air outlet as per approved for
construction shop drawings and the same shall be supported by means of a suitably
approved type of support as per the approved support and hanger details.
6.31. Approved Flexible Duct Connector shall be installed in expansion joints and between
connections of HVAC equipment (packaged units, exhaust fans, etc..) and HVAC ducts by
means of S-type cleat joints and riveted and sealed with approved duct sealant.
6.32. All duct systems shall be identified using labels in compliance with the project
specifications.
6.33. Test hole to be provided and plugged ready for commissioning and control equipment’s.

7. AIR LEAKAGE TEST PROCEDURE

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.

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7.1.10. Instruct installers to use special care when assembling ducts that will be
relatively inaccessible for repair.
7.1.11. Do not overlook leakage potential at access doors.
7.1.12. Do not leave test apparatus unattended.
7.1.13. Avoid excessive blanking, consistent with industry practice, by testing prior to
installation of collars for room air terminals
7.1.14. Take testing seriously; work sequence, work duration and costs can be
significantly affected.
7.1.15. Prior to starting the duct leak testing confirm all duct blank off and seal of all
aperture in the selected length of duct by using blanking plates, caps or
polythene bags, taped to ductwork. Ensure carefully no opening has been
overlooked. Choose a length of duct work to be tested for which the estimated
leakage will not exceed the capacity of the Test apparatus.
7.2. The QA/QC department will inspect the duct sections and issue a punch/snag list if
necessary.
7.3. On satisfactory completion of the inspection and making good such punch items, the
QA/QC department shall issue a request for inspection to the consultant.
7.4. On satisfactory completion of the inspection by the consultant, and making good such
punch items as may be noted by the consultant, the duct sections may be released for
testing.
7.5. All test measuring equipment shall be calibrated, and a certificate of calibration shall be
available for review.
7.6. Ductwork testing shall be conducted in manageable sections to allow construction to
proceed without delays.
7.7. A manometer or approved measuring apparatus shall be used to measure the airflow.
7.8. The duct test pressure shall be sensed only from an opening in the duct.
7.9. Do not test uncured seals
7.10. Connect the blower and flow meter to the duct section and provide temporary seals at
all open ends of the ductwork.
7.11. To prevent over pressurizing of the ducts, start the blower with the variable inlet damper
closed. Controlling pressure carefully, pressurize the duct section to the required level.
7.12. Once the required test pressure has been achieved read the flow meter and compare the
leakage on CFM per square foot with the allowable rate. If it meets the allowable rate the
test certificate shall be completed and signed.
7.13. Prior to the consultant being requested to witness any test, an in-house test shall be
carried out to ensure the nominated duct system is within the allowable leakage rate. In
the event that a test should fail the allowable leakage rate the following shall apply.
7.14. Should the test not meet the allowable rate, the duct work should be closely inspected
for leaks. Any and all leaks shall be repaired. In the event that no significant leaks were
found, consideration should be given to diving the duct section into two or more tests.
7.15. Where significant leakage was discovered they should be repaired and the system re-
pressurized and re-tested.
7.16. Temporary blanks and seals may be left in place until permanent connection is
completed to maintain cleanliness.
7.17. Testing must comply with all the requirements of the Project Specifications under Section
15812.

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7.18. Leakage classification:

Leakage classification identifies a permissible leakage rate in cfm per 100 ft2 of duct
surface according to the relationship CL = F ÷ (P) 0.65.

CL - is a constant obtained for below shown Table-1


F - is the leakage rate in cfm/100 ft2 of duct surface (it varies with static pressure).
P - is the static pressure.
N - is an exponent (most typically it is 0.65 but in some cases it is 0.5 to 0.9)
Values for (P) 0.65 are shown below in Table-1.

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Table-1

LEAKAGE CLASS (CL) UNSEALED

PRESSURE W.G. CLASS CLASS CLASS CLASS CLASS

P0.65 P″ 3 6 12 24 48

0.143 0.05 0.4 0.9 1.7 3.4 6.7

0.224 0.10 0.7 1.3 2.7 5.4 10.7

0.351 0.20 1.1 2.1 4.2 8.4 16.8

0.457 0.30 1.4 2.7 5.5 11.0 21.9

0.551 0.40 1.7 3.3 6.6 13.2 26.4

0.637 0.50 1.9 3.8 7.6 15.3 30.6

0.717 0.60 2.2 4.3 8.6 17.2 34.4

0.793 0.70 2.4 4.8 9.5 19.0 38.1

0.865 0.80 2.6 5.2 10.4 20.8 41.5

0.934 0.90 2.8 5.6 11.2 22.4 44.8

1 1 3 6 12 24 48

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Table-1

LEAKAGE CLASS (CL) UNSEALED

PRESSURE W.G. CLASS CLASS CLASS CLASS CLASS

P0.65 P″ 3 6 12 24 48

1.30 1.5 3.9 7.8 15.6 31.2 62.4

1.57 2.0 4.7 9.4 18.8 37.7 75.4

1.81 2.5 5.4 10.9 21.7 43.4 86.8

2.04 3.0 6.1 12.2 24.5 49.0 98.0

2.26 3.5 6.7 13.6 27.1 54.2 108.5

2.46 4.0 7.4 14.8 29.5 59.0 118.1

2.66 4.5 8.0 16.0

2.85 5.0 8.6 17.1

3.03 5.5 9.1 18.2


3.20 6.0 9.6 19.2
3.54 7.0 10.6 21.2
3.86 8.0 11.6 23.2
4.17 9.0 12.5 25.0
4.47 10.0 13.4 26.8

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Table-1

LEAKAGE CLASS (CL) UNSEALED

PRESSURE W.G. CLASS CLASS CLASS CLASS CLASS

P0.65 P″ 3 6 12 24 48

4.75 11.0 14.3 28.5

CL is the leakage class and is a constant.

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.

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8. RESPONSIBILITIES

8.1. Construction Manager


8.1.1. Shall be responsible for the overall construction activities.

8.2. Site Engineer / Supervisor / General Foreman


8.2.1. Implementation of safe work method statement and risk assessment plan.
8.2.2. Arrange TBT prior to commencement of work.
8.2.3. Visit the area of work for no hazard items exist.
8.2.4. Organizing the site and work places so as to ensure that work is carried out to
the required standard, with minimum risk to men, equipment and materials.

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8.2.5. Ensure that the employees under his responsibility do not engage in unsafe
work practices or take unnecessary risks.

8.3. QA/QC Engineer


8.3.1. Shall ensure that all works are carried out strictly in accordance with approved
method statements and inspections test plans.

8.4. Safety Officer


8.4.1. Enforce the Project HSE rules and regulations.
8.4.2. Implement HSE requirements set out in Mercury MENA HSE Plan
8.4.3. Ensure work permit has been obtained and implemented (if applicable).

8.5. Material Controller


8.5.1. Shall be responsible for receiving materials on site warehouse. He will check the
materials for any damages during shipping, handling and storage.

8.6. Tradesmen / Drivers / Operators / Welders


8.6.1. Follow supervisor’s and/or general foreman’s instructions.
8.6.2. Only authorised drivers / operators can operate the plants.
8.6.3. Only authorized welders can operate welding plants.

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.

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11. PLANT AND EQUIPMENT

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. HEALTH, SAFETY, AND WELFARE

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.

Method Statement for HVAC DUCTWORK & ACCESSORIES


Page 18 of 20
12.7. 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.
12.8. For dusty working environment dust masks shall be used.

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. COMMUNICATION AND TRAINING

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. QUALITY CONTROL

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

Method Statement for HVAC DUCTWORK & ACCESSORIES


Page 19 of 20
ATTACHMENTS

Method Statement for HVAC DUCTWORK & ACCESSORIES


Page 20 of 20
METHOD STATEMENT FOR INSULATION OF DUCTING
SYSTEM

Method Statement for HVAC DUCTWORK & ACCESSORIES


Page 1 of 11
TABLE OF CONTENTS

Section Description Page No

1.0 PURPOSE AND SCOPE 4

2.0 OBJECTIVES 4

3.0 REFERENCE DOCUMENTS 4

4.0 CONSTRUCTION METHODOLOGY 4-11

5.0 RESPONSIBILITIES 11-12

6.0 LIST OF MAIN EQUIPMENT, TOOLS, AND INSTRUMENTS 12

7.0 MATERIAL HANDLING 12-13

8.0 HEALTH, SAFETY, & WELFARE 13

9.0 ENVIRONMENT 14

10.0 COMMUNICATION & TRAINING 14

11.0 FIELD QUALITY CONTROL 14

Method Statement for HVAC DUCTWORK & ACCESSORIES


Page 2 of 11
1. PURPOSE AND SCOPE

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

3.1. Project Specifications


3.2. Project IFC Drawings
3.3. Qatar Construction Standards
3.4. Approved Shop Drawings (as applicable)
3.5. Approved Material Submittal (as applicable)
3.6. Project Quality Plan
3.7. Project HSE Plan

4. CONSTRUCTION METHODOLOGY

4.1. Pre-Installation Checks

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. Application Method for Duct Insulation

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

Method Statement for HVAC DUCTWORK & ACCESSORIES


Page 4 of 11
4.2.9. Refer to Table 1 below as to recommendations for following specific installation
instructions for cutting and fixing Thermo break Sheet.

Table 1

4.2.10. Wrap around insulation system:


4.2.10.1. The adhesive used relies on pressure to properly bond to the duct. Once
fixed, adhesive should be padded firmly to ensure contact with the duct
metal sheet.
4.2.10.2. The adhesive can be re-positioned for better alignment, provided no
pressure is applied and it is done immediately. However, once the
adhesive cures, it will be impossible to re-position or peel off the duct.
4.2.10.3. Cut Thermo break to the required length to wrap around the duct. Always
allow excess 20-30mm for final adjustment. Do not peel the backing paper
off at this stage.
4.2.10.4. Peel off only a small section to start off with (150 mm). Align with duct
edge with the insulation sheet edge, and gently lower to the duct. Pad
firmly. Starting from the fixed edge, move to the other edge by lowering
the insulation to the duct progressively whilst padding insulation at the
same time. Peel off enough paper to cover one side at a time only. Ensure
air is expelled.
4.2.10.5. Do not try to lower entire sheet to one side of the duct at once. This will
lead to trapped air pockets. (Figure 2). Thermobreak is a closed cell
material and will not allow trapped air to escape.

Figure 2

4.2.10.6. Once one side is fixed, continue to the next side.


4.2.10.7. Slowly peel off enough backing paper to cover the edge and side of duct.
Slowly pad the adhesive to the edge; do not pull the insulation on the duct
corners. Guide the insulation over the corner by pressing lightly (Figure 3).

Method Statement for HVAC DUCTWORK & ACCESSORIES


Page 5 of 11
The insulation on the corners should be the same thickness as on the flat
sections.

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

4.2.10.9. Use aluminium foil tape to seal the joint. (Figure 5)

Method Statement for HVAC DUCTWORK & ACCESSORIES


Page 6 of 11
Figure 5

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 9 (Installation of strips around flanges – cut-away view)

Method Statement for HVAC DUCTWORK & ACCESSORIES


Page 7 of 11
Figure 10 (Installation of strips around flanges)

4.2.13. Cut section insulation system:


4.2.13.1. For thickness greater than 20mm, it is advisable to use four cut sections to
insulate the duct.
4.2.13.2. Observe cleaning requirements of the duct as outlined in the pre-works
section.
4.2.13.3. Observe application techniques as explained in previous section relating to
application of insulation. Apply sheets slowly starting from one edge and
then slowly moving to the opposite edge whilst applying pressure at the
same time. Never lay the whole sheet at once as this will lead to air
pockets.
4.2.13.4. Ensure width of sheets is adequate to cover the duct and the extra width
from the adjacent sheets of insulation. (Figure 6)dfggf

Figure 6

4.2.13.5. Observe taping requirements of the duct as per Taping Instructions


(Section 4.2.13).

4.2.14. Taping Instructions:


4.2.14.1. Use recommended width of specified reinforced aluminium foil tape.
4.2.14.2. It is important that the insulation surface to which tape is to be adhered is
free from dust and dirt. If uncertain, clean the surface with a clean rag. In
Method Statement for HVAC DUCTWORK & ACCESSORIES
Page 8 of 11
the case of any oil or silicone contamination, wipe the surface with a clean
rag and suitable cleaning agent, then wait to dry before applying tape.
4.2.14.3. Aluminium foil tapes must be applied using pressure. The more pressure
applied, the more surface contact is achieved and the better the result.
4.2.14.4. The best way to apply this pressure is to repeatedly rub the tape external
surface with a flat blunt object.
4.2.14.5. The vapour barrier should be continuous wherever there is a break in the
Thermobreak foil facing; i.e. no foam surfaces must be exposed after
installation.
4.2.14.6. When applying tape, follow the contours of the material. Do not try to
flatten the contours out with the tape. Let the tape relax into and conform
to the irregularities of the surface, then rub down (refer to Figures 7 and
8) to eliminate air bubbles.

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

5.1. Construction Manager


5.1.1. Shall be responsible for the overall construction activities.

5.2. Site Engineer / Supervisor / General Foreman


5.2.1. Implementation of safe work method statement and risk assessment plan.
5.2.2. Arrange TBT prior to commencement of work.
5.2.3. Visit the area of work for no hazard items exist.
5.2.4. Organizing the site and work places so as to ensure that work is carried out to
the required standard, with minimum risk to men, equipment and materials.
5.2.5. Ensure that the employees under his responsibility do not engage in unsafe
work practices or take unnecessary risks.

5.3. QA/QC Engineer


5.3.1. Shall ensure that all works are carried out strictly in accordance with approved
method statements and inspections test plans.

Method Statement for HVAC DUCTWORK & ACCESSORIES


Page 9 of 11
5.4. Safety Officer
5.4.1. Enforce the Project HSE rules and regulations.
5.4.2. Implement HSE requirements set out in Mercury MENA HSE Plan
5.4.3. Ensure work permit has been obtained and implemented (if applicable).

5.5. Material Controller


5.5.1. Shall be responsible for receiving materials on site warehouse. He will check the
materials for any damages during shipping, handling and storage.

5.6. Tradesmen / Drivers / Operators / Welders


5.6.1. Follow supervisor’s and/or general foreman’s instructions.
5.6.2. Only authorised drivers / operators can operate the plants.
5.6.3. Only authorized welders can operate welding plants.

6. LIST OF MAIN EQUIPMENT, TOOLS, AND INSTRUMENTS

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.

Method Statement for HVAC DUCTWORK & ACCESSORIES


Page 10 of 11
7.10. Manufacturer’s instructions with regard to storage requirements shall form the basis for
material storage and preservation.

8. HEALTH, SAFETY, AND WELFARE

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. COMMUNICATION AND TRAINING

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. QUALITY CONTROL

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

Method Statement for HVAC DUCTWORK & ACCESSORIES


Page 11 of 11
METHOD STATEMENT FOR INSTALLATION OF CHILLED
WATER PIPING SYSTEM

Method Statement for the Installation of


Chilled water Piping System
Page 1 of 17
TABLE OF CONTENTS

Section Description Page No

1.0 Purpose and Scope 4

2.0 Objectives 4

3.0 References 5

4.0 General 5

5.0 Pre- works 5-6

6.0 Works 6-17

7.0 Responsibility 17

8.0 Engineering 17

9.0 Materials 18-19

11.0 Plant and Equipment 19-20

12.0 Health, Safety & Welfare 20

13.0 Environment 21

14.0 Communication and Training 21

15.0 Quality Control 21

Method Statement for the Installation of


Chilled water Piping System
Page 2 of 17
1. PURPOSE AND SCOPE

The purpose of this Method Statement is to outline the methodology to be implemented


for Chilled water piping (Above/Ground) system activities of Worker Hospital & Integrated
Health Centre at Mesaieed Industrial city and to ensure that all works are carried out in
accordance with the approved construction drawings and project specification.

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 methodology contains the construction procedures, the requirements of materials,


manpower, equipment and management thereof.

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

5.1 Installation procedure is to be as per manufacturers recommendations.


5.2 Manufacturer’s recommendations are to be obtained from one of the listed vendor
s in the project specifications/material submittal.
5.3 All workers to attend safety induction training on the safe installation methods by t
he safety department.
5.4 Ensure that pipe & fittings materials received are inspected; found acceptable as p
er approved materials submittal.
5.5 Ensure that all related materials are of approved make and are available before ca
rrying out any work.
5.6 Prior to commencement of work, inspect areas and access to confirm that the site
is ready to commence the work.
5.7 All relevant documentation (drawings) and materials applicable to particular sectio
n of works will be checked by site engineer prior to commencement of work and e
nsure that shop drawings are as of latest revision approved.
5.8 The site engineer/ site supervisor will give necessary instructions to tradesmen (pi
pefitters/installers) and provide necessary construction shop drawings of latest rev
ision.
5.9 The site supervisor/ foremen will also check that proper tools and equipment are a
vailable to carry out the work and are in compliance with contract specifications.
5.10 The Site supervisor and safety officer will explain to the tradesmen regarding saf
ety precautions to be observed.
5.11 Ensure that grid lines, reference levels etc. are marked by main contractor.
5.12 Site supervisor and foremen will carry out a site survey and mark the route of pip
ing as per approved shop drawings. In the event of any discrepancies or difficultie
s in executing the work, these shall be brought to notice of project engineer for cor
rective contractor.
5.13 Site supervisor and foremen will carry out a site survey and mark the route of pip
ing as per approved shop drawings. In the event of any discrepancies or difficultie
s in executing the work, these shall be brought to notice of project engineer for cor

Method Statement for the Installation of


Chilled water Piping System
Page 4 of 17
rective action.
5.14 Co-ordination with other trades will be carried out while marking the route of pipi
ng.

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.

Method Statement for the Installation of


Chilled water Piping System
Page 5 of 17
6.10 Install drains valves at low points in piping system mains and elsewhere as requi
red.
6.11 Equipment condensate drains shall be trapped at equipment connection. Drain li
nes shall run full size to nearest floor drain or as shown on drawings.
6.12 Do not install piping over electrical panel boards, switchgear, switchboards or mo
tor control centres.
6.13 Install piping tight to slabs, beams, columns, walls, and other permanent elemen
ts of the building.
6.14 The Surface and internal pipes & fittings should be cleaned and free from grease
and oil prior to threading.
6.15 Threading for the pipes should be done with appropriate threading machine. Bla
ck steel size up to 50mm will be threaded and size 65mm and above will be welde
d. Weld metal is to be thoroughly fused with base metal at all sections. Welds shal
l be sound metal, free from laps, slag inclusion or other defects.
6.16 Teflon tape/cotton/jute should be wrapped prior to pipe joints.
6.17 For welded pipe and fittings the following shall apply:
a) Fit up the two ends to be welded as per the approved welding
procedure.
b) Tack the two pieces together ensuring a uniform root gap and
internal alignment.
c) Only welders holding a valid welders qualification certificate for the
applicable welding procedure may weld any joints.
d) Each welder shall have a unique identification number. All welds
shall bear this identification number of the welder.
e) Safety policy should be strictly followed in the place of welding.

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.

Method Statement for the Installation of


Chilled water Piping System
Page 7 of 17
Method Statement for the Installation of
Chilled water Piping System
Page 8 of 17
6.32 Piping connection to Valves and Equipment:
Method Statement for the Installation of
Chilled water Piping System
Page 9 of 17
a. DN50 and smaller: 2070 kPa brass seat unions for steel
piping and with heavy semi-flushed brass unions on copper
piping.
b. DN65 and larger: Flat face welding neck flanges for pressure
860kPa and less; raised face welding neck flanges for
pressure above 860kPa.

6.33 Install strainers as indicated on the approved drawing.


6.34 Where piping crosses a building expansion joint approved expansion bellows or
couplings shall be installed as per the manufacturer’s instructions.
6.35 Check to ensure that the correct type and size of gaskets have been installed at
all flanged joints and that the bolt type, size and length are correct.
6.36 On completion of the works all elements of the installation shall be checked to en
sure the installation is in compliance with the specifications.
6.37 Ensure all field engineering changes are approved and noted on the drawings as
“Red Lined”. All additional vents and drains shall be red Lined on the drawings. Re
d Lined drawings shall be returned to the engineering department for the produc
tion of “As Built” drawings.
6.38 Prior to Pressure testing the system shall be inspected and as necessary a snag
/punch list issued by the QA/QC department. On satisfactory completion of the pu
nch list, the client will be requested to inspect the works.
6.39 Only when the client has inspected and such punch items as raised by the client
cleared and approval given for leak testing, can such testing proceed. An in-house
test of the system will be performed prior to inviting the client to inspect the test for
record purposes.
6.40 On satisfactory testing of the system, it shall be released for insulation. Insulation
should not be compressed with support and installation procedure for insulations s
hould be as per manufacturer’s recommendations.
6.41 Provide space to permit insulation applications as per approved material submitt
al and Approved Shop drawings insulation detail.
6.42 Locate groups of pipes parallel to each other, spaced to permit applying full insul
ation and servicing of valves.
6.43 Ensure all the piping installation should follow the clearance from pipe to pipe an
d service to services as per Approved Shop drawings or QCS-2010
6.44 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 identif
ications with flow direction mark for future maintenance
d. Installations of Identifications labels should be as per Man
ufacturers recommendations.

Method Statement for the Installation of


Chilled water Piping System
Page 10 of 17
WATER PRESSURE TEST
A. GENERAL
a) Prior to water pressure test WIR will be raised as per project requirements for a
pproval of installation of piping work. Inspection request for testing will raised w
ith piping portion highlighted on drawing plan offered for testing inspection.
b) Check all supports are installed as per approved drawings and specifications
c) Chilled water piping shall be testing should be 1.5 times of working pressure fo
r minimum 2 hours and final testing with complete system should be for 4 hour
s if in case of drops the leak points should indentified and same replace with n
ew fittings and repeat the procedure and after conforming offer for Inspections.
d) Estimate the piping volume and make arrangement for required quantity of clea
n water.
e) Trained Personnel will conduct the test monitored by a responsible site engine
er and safety department.
f) Arrange for test plug, temporary piping / hose pipe connections for filling and dr
aining the water.
g) Strict and close supervision is necessary before, during, and after the test so to
minimize water damage and/or unnecessary stains to finished items within the
confines of testing location.
h) Always coordinate with safety and construction departments for a safe and met
hodical conduct of testing works. All other MEP discipline supervisory staff shal
l be informed by concerned site engineer before carrying out the tests for preca
utionary measures to protect other MEP services.

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.

C. PROTECTION FROM WATER DAMAGE

a) Eliminate possible sources of water spillages. Where potential sources of leaka


ge during the test, such as pipe to fitting joints, is above or nearby a finished ite
m, provide an adequate protective shield to minimize damage due to water.
b) Furnish adequate number of personnel during the filling up with water to the to
the pipes under test in monitoring pipe joints, so to provide early warning of an
y leaking point, with two - way radio and working flashlights.
c) When a leaking point is known, immediately inform the site supervisor depress
urized the pipelines under test.
d) Inform Client to examine the damaged coating section of pipe before and after
Method Statement for the Installation of
Chilled water Piping System
Page 11 of 17
repair.

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.

E. TESTING WITNESS BY THE CONSULTANT

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.

F. DISPOSAL OF TEST MEDIUM

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

Method Statement for the Installation of


Chilled water Piping System
Page 12 of 17
8. RESPONSIBILITY
All personnel engaged in the installation of Chilled water Piping System activity
shall be adequate experience in their respective discipline
a. Construction Manager is responsible for the overall works.

b. Site Engineer, Surveyor and Foreman is responsible for the installation


activities 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.

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.

k. Pipes can be stack as per any following case, shown in below:

l. Pipes shall be protected from direct sunlight as per manufacturer’s recommend


ation, where ever applicable.
m. While handling the pipes care shall be taken as per manufacturer recommenda
tions to avoid damage to pipe coating.
n. Ends caps will not removed from all pipes until taken out for installation.
o. Delivery of chilled water pipes and fittings will be checked / Inspected by QC e
ngineer to ensure all items on the delivery note are correct prior to signing. Any
shortage or damaged items should be recorded on the delivery note and dama
ge materials will store separate with identification tag or shall be removed from
site.
p. Upon delivery of materials at contractor’s site stores, inspection will be offered f
or Client approval.

11. PLANT AND EQUIPMENT


Method Statement for the Installation of
Chilled water Piping System
Page 14 of 17
a) Pipe Cutter
b) Paint brush
c) Measuring Tape, Plum bob, chalk line, Nylon string line.
d) Ball peen hammer
e) Ladder
f) Spirit Level
g) Pipe fitter standard tool box
h) Socket spanner
i) Screw driver
j) Test Plugs, end caps
k) Ratchet
l) Water level
m) Square drive Rachet spanner
n) Box spanner
o) Allen socket adaptor
p) Calibrated torque wrenches
q) Electric impact screw driver

12. HEALTH,SAFETY & WELFARE

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.

14. COMMUNICATION AND TRAINING


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. QUALITY CONTROL

Significant stages of work shall be monitored and ensured to be enforced by the


concerned as per the Inspection and Test Plan attached to this document.
Inspection request to be submitted to the Engineer a day prior to inspection
schedule.

Quality Control tests on performed work and materials shall be in accordance


with Project Specification

16. ATTACHMENTS

 ITP
 Pressure Test Report
 HSE Risk Assessment

Method Statement for the Installation of


Chilled water Piping System
Page 16 of 17
ATTACHMENTS

Method Statement for the Installation of


Chilled water Piping System
Page 17 of 17
METHOD STATEMENT FOR INSULATION OF CHILLED
WATER PIPING

Method Statement for Insulation of Chilled water Piping


Page 1 of 8
TABLE OF CONTENTS

Section Description Page No

1.0 Purpose and Scope 4

2.0 Objectives 4

3.0 References 4

4.0 General 5

5.0 Pre- works 5-6

6.0 Works 6-40

7.0 Responsibility 40-41

8.0 Engineering 41

9.0 Materials 41-42

10.0 Plant and Equipment 42

11.0 Health, Safety & Welfare 42

12.0 Environment 43

13.0 Communication and Training 43

14.0 Quality Control 43

Method Statement for Insulation of Chilled water Piping


Page 2 of 8
1. PURPOSE AND SCOPE

The purpose of this method statement is to outline the methodology to be implemented


for insulation for chilled water piping system activities of Worker Hospital & Integrated
Health Centre at Mesaieed Industrial city to ensure that all works are carried out in
accordance with the approved construction drawings and project specification.

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 methodology contains the construction procedures, the requirements of materials,


equipment and management thereof.

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

Method Statement for Insulation of Chilled water Piping


Page 3 of 8
4. GENERAL

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.

Method Statement for Insulation of Chilled water Piping


Page 4 of 8
6. WORKS
6.1 Insulation for chilled water piping system

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

Method Statement for Insulation of Chilled water Piping


Page 5 of 8
a) Construction Manager is responsible for the overall works.

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.

Method Statement for Insulation of Chilled water Piping


Page 6 of 8
10. PLANT AND EQUIPMENT
a) Measuring Tape.
b) Step Ladders, Scaffolding.
c) Pipe insulator standard tool box
d) Screw driver
e) Knife/Cutter
f) Rough Cotton Clothes
g) Plain plate for pressing insulation

11. HEALTH,SAFETY & WELFARE

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.

Method Statement for Insulation of Chilled water Piping


Page 7 of 8
13. COMMUNICATION AND TRAINING
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.

14. QUALITY CONTROL


Significant stages of work shall be monitored and ensured to be enforced by the
concerned as per the Inspection and Test Plan attached to this document. Inspection
request to be submitted to the Engineer a day prior to inspection schedule.

Method Statement for Insulation of Chilled water Piping


Page 8 of 8

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