WORK METHOD STATEMENT

(WMS)

PROJECT TITLE:

DESIGN AND BUILD FOR THE PROPOSED NEW ESCALATOR SHAFT

PIT FOUNDATION AND OTHER ASSOCIATED WORKS AT CONTACT
PIER AND SATELLITE BUILDING, KL INTERNATIONAL AIRPORT
TERMINAL 1, SEPANG, SELANGOR DARUL EHSAN

CLIENT

MALAYSIA AIRPORT (SEPANG) SDN BHD

SCOPE OF WORK: MECHANICAL AND ELECTRICAL WORKS

Prepared by: Approved by:

………………………………………………… …………………………………………………………..
Name : Name :
Date : Date :

(to be signed by contractor) (to be signed by PMT)

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INDEX

1.0 OBJECTIVE
2.0 CLIENT INFORMATION
3.0 METHOD OF STATEMENT (METHODOLOGY)
3.1 INTRODUCTION
3.2 GENERAL
3.3 SCOPE
3.3.1 ELECTRICAL WORKS
3.3.1.1 Site Inspection
3.3.1.2 Site Preparation
3.3.1.3 Execution
3.3.1.4 Scope of Works
3.3.1.5 Safety
3.3.2 FIRE FIGHTING WORKS
3.3.2.1 Execution
3.3.2.2 Safety
3.3.3 KITCHEN EXHAUST FAN WORK
3.3.3.1 Preparation of Duct Installation
3.3.3.2 Pre-Fabrication
3.3.3.3 Duct Installation
3.3.3.4 Flexible Duct Flexible Connector Methodology
3.3.3.5 Duct Smoke Test, Light Test, Pressure Test
3.3.3.6 Leakage Class
3.3.3.7 Duct Insulation Procedures
3.3.3.8 Protection of Specific Material
3.3.3.9 Specific Safety Requirement and Precaution Measures
3.3.4 FRESH AIR DUCTING WORKS
3.3.4.1 Purpose
3.3.4.2 Application
3.3.4.3 Method
3.3.4.4 Installation
3.3.4.5 Inspection
3.3.4.6 Safety
3.3.5 SANITARY PIPING WORKS
3.3.5.1 Purpose
3.3.5.2 Storage of Material
3.3.5.3 Preparation
3.3.5.4 Installation of Plumbing Fixtures
3.3.5.5 Install Wall Hanging, Back Outlet Urinal with Gasket Seal
3.3.5.6 Connection
3.3.5.7 Manpower Requirement
3.3.5.8 Material Requirement
3.3.6 GREASE INTERCEPTOR
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1.0 OBJECTIVE

This work method statement covers the demolition works for DESIGN AND BUILD FOR THE
PROPOSED NEW ESCALATOR SHAFT PIT FOUNDATION AND OTHER ASSOCIATED WORKS AT
CONTACT PIER AND SATELLITE BUILDING, KL INTERNATIONAL AIRPORT TERMINAL 1, SEPANG,
SELANGOR DARUL EHSAN
This work method statement provides information concerning method of application to ensure compliance
with contract requirements and drawings besides to perform safe working environment and compliance
with safety requirements.

2.0 CLIENT INFORMATION

Company Name MALAYSIA AIRPORT (SEPANG) SDN BHD

4th Floor, Airport Management Centre
Address KL International Airport
64000 KLIA, Sepang
Selangor Darul Ehsan
Contact Person
Position
Contact Number

Remarks:

3.0 METHOD OF STATEMENT (METHODOLOGY)

3.1 INTRODUCTION

This Method Statement describes the specific safe working methods which will be used to carry out the
work. It gives details of how the work will be carried out and what health and safety issues and controls are
involved.

3.2 GENERAL
3.3 SCOPE
3.3.1 Electrical Works
This section describes electrical works and other items required for complete installation.
3.3.1.1 Site Inspection
 Confirm site hazards; add to list below as necessary; tick site specific hazards below.
 Confirm the locations of services and all the isolation points for the work area.
 Identify the services that cannot be isolated.
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 Advise all staff of all hazards identified and precautions to be taken.

 Toolbox talks to be conducted for all personnel on site prior to project commencing and
to be conducted on a weekly basis throughout project.
3.3.1.2 Site Preparation
 Deliver materials to site, report to client representative and sign in as required. Store
materials in the agreed location.
 Delivery times to be agreed with site personnel and agree on a loading and unloading
procedure.
 Issue safety equipment and personal protective equipment as required.
 Close off the work area to client staff and others as required.
 Keep route(s) to emergency exits clear at all times.
 Erect safety barriers & signage before starting work.
 Issue the necessary certified tools & equipment as required and ensure that all equipment
is in good order and fit for the purpose intended.
3.3.1.3 Execution
 At the start of each shift, note the names and number of personnel on site – for roll call
in the event of an emergency. Site project supervisor to be notified of changes of
personnel
 Remove waste materials to the skip via routes approved by the client’s representative
and agreed by all.
 Keep site and break areas tidy and remove excess materials & food stuffs.
 Break areas to be used to be approved by Site project supervisor or his representative
 When safety systems are temporarily bypassed or out of action, the Site project
supervisor or his representative must be notified and give agreement prior to
commencement and inform all staff of the problem and the expected time for normal
operation.
 Notifications to be given To Site Project supervisor as early as possible in all cases were
possible Label equipment as necessary during this period.
 When the shift is over, inspect the work area, unplug all work equipment, check that all
staff are accounted for, inform Site project supervisor and sign out as required.
 Make sure that all safety systems are returned to full working order where possible if
not possible early notification should be given to the Site project supervisor or his
representative all necessary health & safety precautions should be put in place.
 Notifications to be given To Site Project supervisor as early as possible in all cases were
possible.
 On completion of works, tidy up work area, remove all materials and equipment.
 Inspect and test installation – provide certification as necessary.
3.3.1.4 Scope of Works
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 Making provision for wire points for the ceiling light fittings with 20mm pvc conduits and
accessories and the cable size will be 2.5mm square plus 1.5mm square cable earth. As
per E.E.D. standard and I.E.E. rules and regulation.
 Making provision for power points for switch, sockets and floor box with 25mm pvc
conduits and accessories and the cable size will be 4.0mm square plus 2.5mm square
cable earth. As per E.E.D. standard and I.E.E. rules and regulation.
 Power circuit will be ring main.
 Power supply for FCU units will with 25mm pvc conduit with 2.5mm2 cable plus 1.5mm2
for earth.
 Power supply for water heater units will with 25mm pvc conduit with 2.5mm2 cable plus
1.5mm2 for earth.
 Final termination and earthing at E.D.D. approved DB board and accessories. Earthing
will be as E.D.D. standard.
3.3.1.5 Safety
 Trips, Slips, Falls - Use barriers and signage to restrict access to the work area.
 Maintain good housekeeping.
 Store materials in designated areas only.
 Avoid trailing leads in walkways.
 Ensure adequate lighting.
 Falling Materials Use barriers and signage to restrict access to the work area.
 Use safety helmets c/w straps
 Use ladders safely.
 Use scaffold in areas where ladders cannot be used safely. HSA Code of Practice
 Use safety harnesses when working near openings.
 Confined spaces – ceiling voids; risers HSA Code of Practice - Safe Work in Confined
Spaces
 Emergency routes kept clear at all times.
 Agree alternative routes /alternative time to do work if work area is not available.
 Use additional temporary signage as required.
 Maintain good housekeeping Risk assessment & communication.
 Tools & Equipment
 Electrical test equipment Scaffolding Gloves
 Welding equipment Power tools Hand Tools
 Fire Extinguisher 2-way radios Specialist PPE
 Ladders MEWP Mobile platform
 Core drill / Kango Cutting equipment Safety Harness
 Water Ropes Wall Anchor fixing
3.3.2 Fire Fighting Works
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This section describes fire-fighting works and other items required for complete installation.
3.3.2.1 Execution
 Check Pipe Length: Check the pipe length required based on the approved shop
drawing.
 Marking & Cutting: Mark the desired length on the pipe and cut it by using a hacksaw.
Make sure the pipe is perpendicular to the hacksaw cut.
 Threading: Place the pipe in the threading machine and thread it accordingly. Make sure
the thread of the pipe is in good condition.
 Wrap Teflon Tape: Remove the oil from the pipe end after the threading procedure and
wrap it with Teflon tape.
 Installation: Install the pipe to the screw fitting.
 Select Sprinkler Head & Confirm Location: Select the sprinkler head according to the
approved materials list and ensure that the sprinkler head positions are based on the
approved shop drawing.
 Check Ceiling Tee Installation: Ensure the ceiling tee is being installed and levelled by
other.
 Install Dropper: Install the dropper pipe to the sprinkler range pipe.
 Cleaning: Clean the screw fitting and sprinkler tee joint to ensure they are free of dust.
 Wrapping: Wrap the screw joint of the sprinkler head Teflon tape to prevent leaking.
 Tightening: Install the sprinkler head rosette and sprinkler head to screw joint of the
dropper pipe. Then, tighten the sprinkler head into the screw fitting by using wrench.
 Levelling: Ensure the sprinkler head is level against the ceiling board.
3.3.2.2 Safety
 Proper scaffolding shall be used and safety harness to be used and secured, if required.
 All personal protective equipment shall be used as appropriate according to the nature
of the job.
 Housekeeping shall be of good standard and all of cuts and spills shall be removed.
 Safety belt if required in high level of ceiling.
 Scaffolding tag should be provided while using scaffolding.
 110 V electrical machines should be used
 Lift carrier to be protected properly.
 Wearing of the safety shoes to avoid foot injuries.
 Wearing of safety hat.
 Wearing of safety goggles to protect eyes from dust.
3.3.3 Kitchen Exhaust Fan Works
This section describes kitchen exhaust fan works and other items required for complete
installation.
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3.3.3.1 Preparation of Duct Fabrication

 All workers shall attend safety induction training
 Ensure that B.I. sheet, fittings, and materials received are inspected and found
acceptable as per approved material submittals.
 All documents, shop drawings and material submittals shall be approved and an issued
for construction prior to installation and fabrication.
 Gas Welding shall be carried out by skilled and competent welders for B.I. Steel sheets.
 Working area should be equipped with Safety paraphernalia such as welding cover, fire
blanket, welding helmet, hot work signage’s and adequate Fire Extinguishers.
 Hot works permit must always be secured prior to start of work.
3.3.3.2 Pre-Fabrication
 Measuring: The length of each duct segment will be measured accurately as per IFC.
 Cleaning: Prior to making any joints make sure that duct ends are cleaned inside and
outside. Cleaning will be done using sand cloth, abrasive pads or properly brush. After
cleaning is done, care shall be taken to avoid contact of cleaned duct ends with bare
hands or oily gloves, skin oils, lubricating oils and grease.
 Assembly: Ducts will be assembled after jointing surfaces are properly fluxed. Make sure
that the ducts end to end are properly matched-up using clam. Brazing will be
completed the same day and not left unfinished.
 Welding Flash back arrestor should be installed.
 To set the flame, open the acetylene valve on the torch body about ¼ turn, and use
striker to light the flame.
 Add oxygen until the middle cone just disappears into the inner cone.
 When feeding welding rod, the tip of the rod just barely touch the leading edge of the
puddle.
 Cooling of the weld should be exercised to prevent cracking before release of the vice
clamp.
3.3.3.3 Duct Installation
 Fabricated duct shall be visually inspected.
 Extreme care must be observed while installing the duct to prevent any damage.
 Make sure that proper working platforms are made for safety working.
 Check first fix supports installation are approved.
 Required materials will be delivered from work shop to the site.
 Remove dirt and foreign materials inside of duct if any prior to taking them for
installation at site.
 Assemble the ducts and accessories using only the approved accessories.
 Where require appropriate (approved) sealant, gasket, and tape, to be used to prevent
air leakage.
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 After installation of the duct works, check for correct levelling, position and alignment.
 Install temporary cap to all open ends of ducts before leaving the workplace every day
to minimize ingress of foreign materials.
 Work inspection request will be raised for inspection of installed ducting .
3.3.3.4

Flexible Duct Flexible Connector Methodology

 Cut the connector with the required length.
 Hold seam portion upwards to an angle of 90 degrees, make notches at the where
bending is required.
 Bend the connectors to form the required shape.
 From the end of the connectors cut the metal portion exposing only the fabric with
length of around 2 inches.
 Join the two ends by using rivets or screw.
 Apply liberal amount of adhesive on the fabric portion under the tongue to secure the
seal.

3.3.3.5 Duct Smoke Test, Light Test and Pressure Test

A) Smoke Test (Option 1)
I. The duct system of a certain area to be tested shall be checked if it
complies with the requirements based on plan and specification.
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II. Provide temporary end cap with 6ӯ opening, adjustable to closed and
open position.
III. Prepare all necessary testing forms for smoke leak testing.
IV. Fogger machine uses instrument with butane that ignites to produce
heat through coil where diesel oil pass to build up smoke to be blown
away by A cassette type blower.
V. Closed the opening where the fogger machine was inserted.
VI. Detect all leaks. Repair as necessary and mark in the key plan for future
reference.
VII. Provide key plan for the duct system to be tested including shop
drawing to identify the exact location or the area under consideration.
VIII. All concern representatives must be present during smoke testing.
IX. Complete test report and obtain witness signature.
X. Remove temporary blanks and seals.
XI. Repeat smoke testing step 4 to 6 as necessary.
B) Light Test (Option 2)
I. Locate the area and duct system that is to be considered for light test.
II. Prepare the materials that are to be used for light testing and
rectification of the duct condition to ensure safety in carrying out the
procedure.
III. Make sure that the area has minimal outside light in order to perform
an optimum light test.
IV. Cover one end of the duct, enough to cover the entire opening of the
duct.
V. Switch on the halogen light and position it inside the other end of the
duct, cover this end as well.
VI. Perform visual inspection to see any potential leak on areas as to where
light may have been passing through from the inside of the duct.
VII. Rectify areas as to where there are potential leaks using duct sealant.
VIII. Make sure that there are no potential leaks as the light test is
performed.
IX. All concerned representatives must be present during light test.
X. Complete test report and obtain witness signature.
XI. Remove end covers after testing procedure and provide plastic film to
protect the duct from dust.
C) Pressure Test (Option 3)
I. Conventional leak testing is based on positive pressure mode analysis. It
involves in temporary plugs. In openings in a section of duct connecting
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a blower and a flow meter to the specimen in such a manner that

pressurization specimen will cause all air escaping from the duct to pass
through the flow meter.
II. Select a test pressure not in excess of the pressure class rating of the
duct.
III. Calculate the allowable or allocated leakage using leakage factors
related to the duct area.
IV. Select a limited section of duct for which the estimated leakage will not
exceed the capacity test apparatus.
V. Connect the blower and flow meter to the duct section and provide
temporary seals at the ends of the ductwork.
VI. To prevent over pressurizing of the ducts, start the blower with the
variable inlet damper. Controlling pressure carefully, pressurize the duct
section to the required level.
VII. Read the flow meter and compare the leakage in cfm per square foot
with the allowable.
 Inspect the pressurized duct and all connections between the flow
meter and the duct sensible leaks.
 Depressurize; repair all audible and other significant leaks. If the
first pressurization develops the required test pressure level and
significant leak sites were not discovered, consider the following
alternatives divide the specimen being tested into smaller segment
use larger test apparatus.
 Allow repaired seals to cure and retest until the leakage rate is
acceptable.
VIII. Complete test reports and obtain witness signature.
IX. Remove blanks and seals.
 Verify that an adequate and matched electric power source is
available for the blower.
 Determine that the capacity of the blower is suitable for the
amount of duct tested.
 Isolate equipment (fans, in-line flanged coils, volume regulating
boxes, etc.) from ductwork. The system designer should have
independently accounted for leakage.
 Anticipate difficulty with any test of ductwork that has no
prescription for sealing yet is to meet an allowable leakage level.
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 Do not over pressurize ducts. Provide pressure control or pressure

relief if test behavior is unfamiliar, e.g. start test blower with flow
restricted and gradually pressurize.
 Do not test uncured seals.
 Conduct required test before external insulation is applied.
 Don't overlook leakage potential at access doors.
 Do not leave test blower & inclined manometer unattended.
3.3.3.6 Leakage Class

 Leakage classes apply when the designer does not designate other limits and has
specified seal class 24 and 2” W.G.
 Unsealed rectangular metal duct may follow leakage class 48.
 Although seal class A or B might be assigned for lower pressures, the leakage class
achieved may not conform to those associated with the higher pressure. Other
construction details influence results.
 Leakage class C (C1) is defined as being the leakage rate (CFM/100 S.F.) divided by P65
where P is the static pressure (in W.G.). When P is numerically equal to 1” the leakage
rate is C1.
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 The duct pressure classification is neither the fan static pressure nor the external static
pressure (on an HVAC unit) unless RG Punzalan the Design consultant has made such an
assignment in his Mechanical Layout. Unless construction class is otherwise specified, it
means a static operating pressure in the duct as follows.

 Precautions to be followed for test apparatus.

 Start the blower with blocked suction or discharge to avoid over pressurizing
ductwork.
 Use clean manometers.
 Heat manometers to avoid freezing fluid in cold weather.
 If manometer fluid is blown out refill with the appropriate fluid for
convenience adds a drop soluble dye to water-filled manometers.
 Level position sensitive instruments and set them to zero scale reading.
 Read liquids levels by viewing them horizontally.
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3.3.3.7 Duct Insulation Procedures

After the installation and testing of kitchen exhaust airduct was approved and accepted by
the client representative, proceed with the insulation.
Insulation using the Stud Welding Equipment:
 Set up the stud welding equipment (LYNX Modular Stud Welding System) following the
safety guidelines and proper installation. The electrucal connecting cable used for mains
operation is of adequate length. Additional extension cables cause a voltage drop,
possibly leading to unit disturbances.
 Wipe/clean the surface of the installed pre-painted duct with clean cloth and be sure
that the dust or foreign materials are totally removed.
 Cut a desired size of Rockwool insulation using a blade cutter.
 Install the approved insulation materials to duct surface and press firmly so that 100%
full contact with the duct surface and cut insulation was achieved.
 Welding parameters:
The charge voltage is selected based on the diameter of the fastener. These
estimated voltages listed below are for “flanged” fasteners and may not be
appropriate for mini-flange, DIN, or non-flange fasteners. Voltage should be adjusted
for your particular application.

In the above chart, “GUN” indicates the spring pressure setting on the ITW-G1 gap
gun. “-“indicates decreased spring pressure on the gun spindle. “+” indicates
increased spring pressure on the gun spindle resulting in greater velocity at the
instant the weld is made.
 Using the stud welding machine, position the weld pistol with a fastener in the gun on
the work piece. The „Stud On Work“ LED will be lit. Depress to trigger on the welding
gun. In gap mode only, the „Foot On Work“ light will activate. Pull the trigger rapidly to
discharge the unit.
 After the stud is welded, remove the gun from the stud by pulling the gun away
perpendicular to the work surface. The „Weld Complete“ light will activate momentarily
and the unit will recharge. Upon successful recharge, the „Ready“ light will turn on. An
interval of a maximum of 300mm is required for the welding on all sides.
 Put duct tape on the Rockwool insulation joints.
 Provide protection as necessary.
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3.3.3.8 Protection of Specific Material

 Materials will be delivered to the site in undamaged condition.
 Do not unload damaged duct. All damaged duct to be returned to the factory.
 All related documents i.e. delivery note, bill of lading, country of origin, mill certification
shall be available along with materials.
 Materials will be offloaded and stored according to manufacturer’s recommendation.
 Materials will be handled and off loaded carefully to prevent any damage %
deterioration.
 Timber supports of suitable size shall be placed at equal distance below the ducts.
 Materials will be stored in dry location.
 Duct shall be stacked on the flat surface free from any sharp object and shall be given
adequate supports at all times.
 Only small ducts shall be stacked and tacking it shall be ensured that ducts of bigger
sizes will be placed at the bottom and smaller sizes at the top.
 Sufficient workers must be used when handling the duct to avoid injuries/ strains to the
workers when physically moving the ducts by hand.
 Delivery if materials will be check by MDBI staff to ensure all items on the delivery note
are complying with approved materials submittals, project specification and approved
drawings. Any shortage, damaged and/or unapproved items should be recorded on the
delivery note.
3.3.3.9 Specific Safety Requirement & Precaution Measures
 Notify the store on delivery dates.
 Ensure that all workers involved in the operation are wearing PPE all the time.
 Ensure workers are fit to working and lifting ductworks.
 Brief workers rules and responsibilities before start work.
 Ensure that transportation route is clear of obstruction.
 Ensure that the designated hoisting area is clear of obstruction.
 Ensure the proper lifting methods are being followed.
 Clean up the working area.
 Prevent development of safety hazards.
 Store tools, equipment’s and non-used materials properly at the end of workday.
 Follow safe work practice. Gloves should be worn when handling ducts to prevent cuts
on sharp edges.
 If any accident occurs, it will be immediately reported to MDBI HSE manager. Concerned
Project Manager, Client’s representative, relevant authority, and if required, emergency
services will be called for medical treatment.
 Wear safety glasses, PPE and chemically resistant gloves when using the duct sealant.
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 Safe access to the place of work shall be provided for all employees, including
installation at height.

3.3.4 Fresh Air Ducting Works

This section describes kitchen exhaust fan works and other items required for complete
installation.
3.3.4.1 Purposed
The purpose of this method statement is to outline the method of storage and
installation of fresh air ductwork.
3.3.4.2 Application
G.I. Sheet metal ducts are used for exhaust ducting. Pre-insulated ducts are used for
supply, return and treated fresh air ducting.
3.3.4.3 Materials
 Pre-fabricated ducts made of pre-insulated panels.
 Flanges and cleats for joining the G.I. ducts factory fabricated of G.I. Sheet steel as
per SMACNA HVAC construction standards 1985.
 Aluminium flanges and profiles, PVC cleats, etc., for joining of pre-insulated ducts
as per approved submittals.
 Threaded rods, G.I. angles, etc., for supporting system.
 Duct sealant, Gaskets & Adhesives.
 VCDs, Fire dampers and Access doors as per approved submittals/samples.
3.3.4.3 Method
i) Storage
 When off-loading, the ducts shall be carefully lowered to ensure no damage
to edges or duct surface.
 All ducts shall be stored properly to safeguard ducts from any abrasions and
damages.
 All delivered ducts will be stacked and covered by polythene sheets to
protect from dust etc.
 Duct sealant, adhesive, gaskets, etc., shall be stored in enclosed area in as
per manufacturer’s recommendations.
ii) Preparation
 Ducts are pre-fabricated in the workshop and longitudinally assembled to a
maximum length of 4m. Preparation for the traverse joints including the
fixing of the flanges/profiles as applicable as per the construction schedule
is carried out at workshop. Please refer attached Annexure-II (revised).
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 Ducts received at site as above shall be joined together on the floor to form
manageable lengths.
 Branch take-off collars are tap-in glued type and will have shoe
configuration at the take-offs. Wherever branch take-offs are to be made,
suitable cut out shall be made on the main duct with 45° angle cutter to
form the 45° female part of the joint. The branch/take-offs with 45° male
cut ends are secured to the main duct by the joining glue. The joint is sealed
with approved duct sealant and finished with self-adhesive aluminium foil
tape.
 Wherever flexible ducts are to be fixed, pre-fabricated G.I. collars of
required diameter are fixed to the main duct by means of a prefabricated
groove on the collar (to prevent the inward movement against the panel
face) and dovetail folding at the inner side of the panel. Approved duct
sealant is applied at the joint.
3.3.4.4 Installation
 The layout of duct to be installed shall be as per approved drawing.
 Position of duct supports shall be marked on the underside of the slab / structural
member/vertical walls as the case may be and mechanical anchor fasteners shall be
installed in slab or suitable clamps shall be installed if support to be taken from
structural member, to facilitate suspension of threaded rods for duct trapeze
support. The support details and spacing shall be as per the DW 144 / approved
drawings for G.I. ducts and as per manufacturer’s recommendation for pre-insulated
ducts.
 Threaded rod of suitable size as per DW144 shall be fixed to the mechanical anchor
fastener / clamps using proper lock nut. G.I. angle, cut to required size of duct (to
have clearance of 50mm on either side) shall be fixed to the threaded rod suspension
and locked in position by suitable zinc coated nuts and washers.
 Assembled, as above, ducts shall be lifted and shall be installed on trapeze. Similarly
the next length of duct shall be erected and two are joined together by means of
suitable cleats, zinc coated bolts, nuts, washers, gaskets, etc., as applicable as per the
construction schedules for G.I ducts. Care shall be taken to seal the corners and
transverse joints with approved duct sealant. Pre-insulated ducts are joined either by
glue in type male & female joints or with PVC H bayonet cleats for flanged joints as
applicable as per the construction schedule. Duct sealant is applied at the male and
female joint and finished by self-adhesive aluminum tape. For flanged joints, sealant
is applied on all 4 corners and the corners are finished with PVC lock-in type corner
caps.
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 On laying the ducts as detailed above to form the required layout, the ducts shall be
properly aligned and levelled to maintain B.O.D. and distances as per approved
drawing.
 Riser / Shaft Ducts: Necessary scaffolding arrangement to suit site conditions shall be
made. Duct supports shall be taken at each floor / vertical wall as the case may be
and shall be as per approved drawings. Successive ducts shall be installed starting
from low level as the successive higher floors are constructed. The open end of the
upper most ducts shall be sealed properly.
 The insulation of the flexible ducts shall be rolled up to 100mm from the edges and
the flexible duct shall be slipped on to the collar fixed on the main duct and shall be
secured firmly using G.I. Straps and clips. Then the insulation of flexible duct shall be
rolled back and fixed firmly on to spigots and adjoining duct surface and finished
with self-adhesive aluminium foil tape.
 Flexible ducts installed as above shall be supported using 25mm G.I. strip wound
around the duct and suspended from slab if the flexible duct length exceeds 1 metre.
Suitable plenum box as applicable shall be connected to main duct through pre-
insulated flexible ducts. These diffuser plenums shall be prefabricated as detailed
above, connection through round collars fixed to plenum. Diffuser plenum boxes
shall be suspended from underside of slab using central hanger made of galvanized
threaded rod fixed to mechanical anchor fastener and secured using zinc coated nuts
and washers. The single rod suspension shall be limited to square diffuser plenums of
size upto 300mm and multiple suspensions shall be provided for higher size. For slot
diffuser plenum boxes suspension rod shall be provided on center of two shorter
sides of the plenum.
 Manual volume control dampers as approved shall be fixed in the ducting system
wherever mentioned in the drawing. The type of fixation shall be a companion
flange. Care shall take to allow the operation of VCD handles.
 Insulation of VCDs installed in the pre-insulated ducts shall be carried out using
closed cell electrometric foam insulation.
 Fire damper shall be installed as per approved drawing / manufacturer installation
details.
 Access doors shall be provided for fire dampers wherever applicable. Suitable cut out
to suit the size of the access door shall be made in the duct either in the bottom or
side as per site conditions. The mounting frame of access door is fixed to the duct
using dovetail joint system for G.I. ducts or with aluminium profiles glued-in type for
pre-insulated ducts. The door is secured in position within the mounting frame using
cam locks provided in the access door. The access door shall be pre-insulated panel
type for pre-insulated ducts and double skin type with sandwiched insulation for G.I.
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ducts. For smaller duct sizes where providing access door is not feasible, access to
the fire damper will be made through a small length of duct removable by providing
flanged joints (Refer sketch attached vide Annexure-III).
 Diffusers plenum/droppers shall be leveled properly to suit false ceiling.
 The ducts are identified (service wise) as per approved identification labels
(directional arrows).

3.3.4.4 Inspection
 After the duct installation ETA’s QC shall inspect the complete installation and offer
the same for consultant’s inspection.
 On fixation of final fix items like grilles / diffusers etc, consultant’s engineer shall be
invited for final inspection and certification.
3.3.4.5 Safety
 Safety precautions shall be followed inline with established project safety plan.
 People shall use PPE such as safety harnesses, safety shoes, helmets, etc.
 Safety Officer shall check and ensure that all safety precautions are taken before
starting the work in the shafts and heights (including proper lighting and ventilation
in the shafts).
 Safety Officer shall check and ensure that all scaffoldings used are having duly signed
tags.
3.3.5 Sanitary Piping Work
This section describes kitchen exhaust fan works and other items required for complete
installation.
3.3.5.1 Purpose
The purpose of this method statement is to outline the method of storage and
installation of fresh air ductwork.
3.3.5.2 Storage of Materials

 Loading and unloading of delivered plumbing fixtures and accessories and

relevant materials shall be carried out manually or mechanically.

 Handling to be strict as per manufacturer’s recommendation and as necessary, in

a protective packing, crating, and covering. Retain the original protection from
the manufacturer until the area for installation is ready.

 On the receipt of the material, a visual check will be made to ensure that the
components comply with the approved schedules, packing list, and installation
drawings.

 The shifting activity is to be planned.

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 Store sanitary fixtures on elevated platforms in a dry location.

 If plumbing fixtures and accessories are not to be installed immediately after the
delivery at the site, store plumbing fixtures on elevated platforms and dry
locations without hindering the safety of the personnel. The storage area to be
identified.

 All the equipment & accessories that will be transported on the site will be
inspected thoroughly and travelled on the specified routes of the contractor and
unload at the specified place near the workplace.

 Extra precautions will be implemented during transporting of all materials and

equipment and carefully following all the traffic signs while inside the project site.

3.3.5.3 Preparation

 Verify if the area for installation is ready & works related to other disciplines are
completed prior to starting the installation.

  Inform in advance the responsible person if any foreseen problem occurs.

 Examine roughing-in for potable, hot- and cold water supply piping systems; soil,
waste, and vent piping systems; and supports. Verify that locations and sizes of
piping and locations and types of supports match those indicated, before
installing and connecting fixtures. Use the manufacturer’s roughing-in data when
roughing-in data are not indicated.

 Examine walls, floors, and cabinets for suitable conditions where fixtures are to
be installed.

 Do not proceed until unsatisfactory conditions have been corrected.

3.3.5.4 Installation of plumbing fixtures

 Assemble plumbing fixtures and trim, fittings, faucets, and other components
according to the manufacturer’s written instructions.

 Install fixtures level and plumb according to manufacturers’ written instructions,

roughing-in drawings, approved architectural layouts, and referenced standards.

 Install wall-hanging, back-outlet water closets with support manufacturer’s tiling

frame or setting gauge. Install toilet seats on water closets as specified

3.3.5.5 Install wall hanging, back outlet urinal with gasket seal

 Fasten wall-hanging plumbing fixtures securely to supports attached to building

substrate when supports are specified, and to building wall construction where
no support is indicated.
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 Fasten floor-mounted fixtures to the substrate. Fasten fixtures having holes for
securing fixtures to wall construction, to reinforcement built into walls.

 Fasten recessed, wall-mounted fittings to reinforcement built into walls.

 Fasten wall-mounted fittings to reinforcement built into walls.
 Fasten counter-mounting plumbing fixtures to casework.
 Secure supplies to supports or substrates within pipe space behind the fixture.
 Set shower receptors and mop basins in leveling bed of cement grout.
 Install individual stop valves in each water supply to the fixture. Use a gate or
globe valve where a specific stop valve is not specified. Omit stop valves on
supplies to emergency equipment

 Install water-supply stop valves inaccessible locations.

 Install faucet laminar-flow fittings with specified flow rates and patterns in faucet
spouts when faucets are not available with the required rates and patterns.
Include adapters when required.

 Install shower and flow-control fittings with specified maximum flow rates in
shower arms.

 Install traps on fixture outlets. Omit traps on fixtures having integral traps. Omit
traps on indirect wastes, except where otherwise indicated.

 Install disposers in sink outlets. Install switch where indicated, or in-wall adjacent
to sink if the location is not indicated.

 Install escutcheons at the wall, floor, and ceiling penetrations in exposed, finished
locations and within cabinets. Use deep-pattern escutcheons were required to
conceal protruding pipe fittings.

 Seal joints between fixtures and walls, floors, and counters using sanitary-type
silicone sealant according to sealing requirements specified by the manufacturer.

 The location, elevation, orientation, and type of fixtures shall be as per approved
architectural layouts, Materials submittals & manufacturer’s datasheets. 

3.3.5.6 Connection

 Drawings indicate the general arrangement of piping, fittings, and specialties.

 Install piping connections between plumbing fixtures and piping systems and
plumbing equipment specified in the approved shop drawings/details

 Supply and Waste Connections to Plumbing Fixtures:

Refer to product sheets/detail drawings for fitting sizes and connection
requirements for each plumbing fixture.
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 Supply and Waste Connections to Equipment Specified in Other Sections:

Connect equipment with supply inlets, supply stops, supply risers, and traps
specified in product data sheets/detail drawings. Use fitting sizes required to
match connected equipment. Connect fittings to plumbing piping.

3.3.5.7 Manpower Requirement

 Subject to the main contractor’s program and scope/area available for MEP
activities, but not limited to below:

a) Chargehands
b) Plumbers
c) Helpers

3.3.5.8 Material Requirement

 Ensure materials being used are of approved manufacturer/material submittal

from the project vendor list and of quality as specified.
 Approved type & make of sanitary ware fixtures & fittings, approved carriers for
fixtures recommended type of sealant, etc.

3.3.6 Grease Interceptor

Grease interceptors and grease traps, when required, shall be installed as follows:
1. Grease interceptors and grease traps shall be installed at the expense of the owner or
operator of the FSE or owner of the building or facility in which the FSE is located which is
contributing wastewater to the POTW.
2. All wastewater streams containing FOG or reasonably likely to contain FOG within FSEs or
other FOG generating operations shall be directed into one or more appropriately sized
grease interceptor before discharge to the POTW. Grease interceptors shall be either
sized by adding the peak design flow rates for all fixtures leading to the grease interceptor
and allowing a minimum retention time of thirty (30) minutes or as follows:
Grease Interceptor Sizing
a) Peak Meal per Hour
i) Seating capacity of FSE
ii) Occupancy of FSE
iii) Seating or Capacity x meal factor of 1.3 (45 minutes meal) or 1.0
(intermittent use of FSE) = peak meal per hour
b) Waste flow rate / gallons of flow
i) Commercial, equipped kitchen with dishwasher & one garbage
disposal*     7
ii) Commercial, equipped kitchen with dishwasher, no garbage
disposal     6
iii) Commercial, equipped kitchen with no dishwasher, one garbage
disposal*     6
iv) Commercial, equipped kitchen with no dishwasher, no garbage
disposal     5
v) Single service kitchen**  
* Each additional garbage disposal, add one (1) gallon
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**Single service kitchen = no garbage disposal, no dishwasher and

all service is single use
c) Retention time, hours
i) Commercial kitchen                          2.5
ii) Single service kitchen                       1.5
d) Storage factor
i) Commercial Kitchen up to 8 hours of operation              1
ii) Commercial kitchen up to 12 hours of operation             1.5
iii) Commercial kitchen up to 16 hours of operation              2
iv) Commercial kitchen up to 20 hours of operation              2.5
v) Commercial kitchen up to 24 hours of operation              3
vi) Single service kitchen                       1.5

Peak Meal per hour X Waste Flow Rate X Retention Time X Storage Factor = Calculated Interceptor Size

3. Concrete grease interceptors whether precast or poured in place, shall be designed and
manufactured in accordance with ASTM C 1613-08 Standard Specification for Precast
Concrete Grease Interceptor Tanks or IAPMO/ANSI Z1001 Grease Interceptors and shall
be installed in accordance with the codes adopted by the jurisdiction in which the FSE is
located. Where no code is adopted, the construction and installation shall be in
accordance with the Iowa State Plumbing Code and this division. Grease interceptors
using materials other than concrete require approval by the director, and shall comply
with the conditions of such approval, if any.
4. The building official or other designated official of the governmental subdivision within
which the FSE is located shall inspect each grease interceptor installation made pursuant
to this division, shall review all relevant information regarding the rated performance of
the grease interceptor, and the building plan and facility site plan for the building and site
where the grease interceptor has been installed, and shall approve such grease
interceptor installation upon determination that the grease interceptor meets all
applicable standards and requirements.
5. Grease interceptors shall have a minimum capacity of one thousand (1000) gallons and
shall not exceed five thousand (5000) gallons for a single unit. Where a capacity greater
than five thousand (5000) gallons is required, several smaller units shall be installed in
series; however, the capacity shall not exceed ten thousand (10,000) gallons for any single
series of interceptors without approval of the director.
6. Grease interceptors shall be installed outside the building housing the food service
establishment and below surface grade, and shall have access manholes, with a minimum
diameter of twenty-four (24) inches, over each chamber and sanitary tee. Access
manholes shall extend from the grease interceptor to at least the finished surface grade
and be designed and maintained to prevent storm or surface water inflow and
groundwater infiltration. The manholes shall also have readily removable covers to
facilitate inspection and grease removal.
7. Sewer lines which are not grease laden, which are not likely to contain FOG, or which
contain sanitary wastes shall not be connected to a grease interceptor.
8. Grease interceptors shall be equipped with an accessible discharge sampling port with a
minimum six-inch diameter, which shall extend from the grease interceptor to at least the
finished surface grade.
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9. Where grease interceptors are shared by more than one food service establishment, the
building owner shall be the responsible party for record keeping and cleaning of the
interceptor.