HKN MST Me 0321 Rev. D DRR

Document Review Report
Project Waterfront Integrated Resort, Colombo Seq. No. 5440

Issued By The Engineer to the Contract Date 20.02.2019
Contractor’s
HKN-TRANSMIT- 044811
Contractor Transmittal
HKN 12.02.2019
No.
To HKN *Status
A - Approved
B – Approved – subject to incorporating
comments
C - Not approved - resubmit
D - Rejected
Contractor’s Doc. Status Code* Expected
Rev. Description
Ref. No. Re-Issue Date
Method statement for HDPE Pipe

Extension from Retaining Wall to
HKN-MST-ME-0321 D A
External Manhole for Waste and
Rain Water Pipe Network
Comments
From: Reviewed by:

BALMOND STUDIO
78 Glennie Street Colombo
02 • Kavindu Jayawardana – Mechanical Engineering Consultant
Sri Lanka • Antoni Mathias – Balmond Studio
• Janaka Ruwanpathirana – Balmond Studio
+94 (0) 11 2304476 • Miguel Urbano – Balmond Studio
www.balmondstudio.com
Acknowledged Receipt Date:
Signature Name:
SUBMITTAL
To : Balmond Studio Date : 12-Feb-2019
Attn. : Mr. Jeremy Mayhew Response Due Date : 26-Feb-2019
[WR 21] Method statement for HDPE Pipe Extension from Retaining Wall to External Manhole for Waste and
Subject :
Rain Water Pipe Network
Pursuant to Contract Conditions 4.1(ii), we submit herewith the following documents for the review by the Employer's Personnel. We affirm that the
Submittals are in full compliance with the Contract; and where it does not comply, they are expressly stipulated in the relevant parts accordingly. Please
furnish the requisite response with details to us on or before the Response Due Date as indicated above, failing which there is likely to be delay or
disruption to be suffered due to the delay.
Please see attached:

Drawing Shop drawing Material Document
X Method statement Others :
(specify)
For your
X Approval Review Information
Doc.
Doc. No Description Rev. No Zone
Type
[WR 21] Method statement for HDPE Pipe Extension from
Project
HKN-MST-ME-0321 MST Retaining Wall to External Manhole for Waste and Rain Water D
Wide
Pipe Network
From :
Mechanical Manager / Shin Won Jai
Name/Designation
BALMOND/STUDIO DOCUMENT REVIEW REPORT

Project Waterfront Integrated Resort, Colombo 02 * Status
A - Approved
Doc. Status B- Approved - subject to incorporating comments
No. Code* C - Not approved - resubmit
D - Rejected
Comments:
From : Reviewed by:

BALMOND STUDIO
78 Glennie Street
Colombo 02
Sri Lanka Name/Designation
+94 (0) 11 2304476
www.balmondstudio.com
Page: 2/92
Method Statement for HDPE Pipe Extension
Date & Version: 08-02-2019 Rev. D
from Retaining Wall to External Manhole for HKN-MST-ME-0321
Owner: HKN Waste and Rain Water Pipe Network
Project: Waterfront Integrated Resort

Colombo, Sri Lanka
Sub-Contractor:
Dae Jung E & C (Pvt) Ltd

FRIGI E & S (Pvt) Ltd
MUKYUNG E & C Co., Ltd
[WR21] Method Statement for HDPE Pipe

Extension from Retaining Wall to External
Manhole for Waste and Rain Water Pipe Network
Page: 4/92 Method Statement for HDPE Pipe Extension
COMMENT RESPONSE SHEET
Reference
No Engineer’s Comments Contractor’s Reply
/Page No.
Testing pressure should not be lower than

1. Amended accordingly. 49
3.5 bar
4
CONTENTS
AUTHORIZATION AND VERSION HISTORY ............................................................................................. 3
SECTION 1: GENERAL INFORMATION ...................................................................................................... 6
SECTION 2: DESCRIPTION OF WORK ...................................................................................................... 13
2.1. Purpose ................................................................................................................................ 13
2.2. Scope of Work...................................................................................................................... 13
2.3. System Description .............................................................................................................. 13
2.4. List of Materials ................................................................................................................... 15
2.5. Material Storage ................................................................................................................. 15
2.6. Key Plan of Installation ........................................................................................................ 16
2.7. Work Quality Flow Chart ..................................................................................................... 17
2.8. Method Statement Submission Plan ................................................................................... 18
SECTION 3: INSTALLATION METHODOLOGY ......................................................................................... 20
3.1. Inspect Material .................................................................................................................. 20
3.2. Setting Out........................................................................................................................... 20
3.3. Excavation Pipe Trenchers ................................................................................................... 20
3.4. Concrete Bedding ................................................................................................................ 21
3.5. Pipe fabrication ................................................................................................................... 21
3.5.1 Pre fabrication ................................................................................................................................ 21
3.5.2 On site fabrication .......................................................................................................................... 37
3.6. Pipe Installation ................................................................................................................... 37
3.6.1. Installation of pipe support for Underground HDPE pipes ............................................................. 38
3.6.2. Installation of pipe support for Vertical HDPE pipes inside the manhole ...................................... 39
3.6.3. Installation of Underground HDPE pipes ........................................................................................ 40
3.6.4. Installation of vertical HDPE pipes inside the Manhole ................................................................. 40
3.7. Puddle flange and pipe fixing in Box openings. ................................................................... 41
3.7.1. Puddle flange fixing in the retaining wall box opening .................................................................. 41
3.7.2. Pipe installation on Manhole box opening ..................................................................................... 44
3.8. Testing ................................................................................................................................. 48
3.8.1. Leak Test ........................................................................................................................................ 48
3.8.2. Pressure Test .................................................................................................................................. 49
3.9. Concrete encasement .......................................................................................................... 50
SECTION 4: PROJECT SCHEDULE ............................................................................................................ 51
SECTION 5: RISK ASSESSMENT............................................................................................................... 52
5.1 Detail Risk Assessment Sheet .............................................................................................. 52
5.2 Personal Protective Equipment ........................................................................................... 73
5.3 Confined Space Permit......................................................................................................... 74
5.4 Hot work Permit .................................................................................................................. 78
5.5 Pressure Testing Work Permit ............................................................................................. 80
5.6 CoSHH .................................................................................................................................. 81
SECTION 6: TESTING & INSPECTION PLAN ............................................................................................. 81
6.1 Terms and Definition ........................................................................................................... 81
6.2 Inspection Level ................................................................................................................... 82
6.3 Inspection List and Level ...................................................................................................... 83
6.4 Check Lists ........................................................................................................................... 84
5
SECTION 1: GENERAL INFORMATION
Project: Waterfront Integrated Resort

Ref No: ME/0321 Package: HDPE Pipe Extension from Date: 08-02-2019
Retaining Wall and External Manhole for
Waste and Rain Water Pipe Network
To be read in conjunction with Risk Assessment No. RA ME-0321
To be read in conjunction with Manual Handling Assessment No. MHA ME-0321
To be read in conjunction with Personal Protective Equipment No. PPE ME-0321
To be read in conjunction with Logistic Plan HKN-PLC CN-0001
To be read in conjunction with Method Statement for Scaffolding works HKN-MST CN-0084
To be read in conjunction with Emergency Response Procedure HKN-PRC HS-0002
To be read in conjunction with Quality Test Plan HKN-PLN QA-0002
To be read in conjunction with Health and Safety Plan HKN-PLN HS-0001
Refer to CoSHH
assessment status
To be read in conjunction with COSHH Assessments No. HKN-CoSHH
section 5.6(Refer
page 81)
Activity : Installation of HDPE Pipe Extension from Retaining Wall to External Manhole for Waste and Rain
Water Pipe Network
Location : Project wide
Times : Monday to Friday 08.00 to 17.00 Saturday 08.00 to 13.00
Manpower Required :
HKN Sub. Con.
 Construction Manager  Construction Manager
 Engineers(Site & QA/QC)  Engineers(Site & QA/QC)
 Surveyor  Surveyor
 HSE Manager  HSE Officer
 HSE Officer  Supervisor
 Scaffolding Supervisor  Plumber (Fitter)
 Scaffolding Inspector  Electrician
 Store Keeper
(Note: Refer page 9-12 for Roles and Responsibilities)  Scaffolder
 Labourer & Helper
Equipment
Tools/Plant Required Personal Protective Equipment
Safety Helmet Including Chin Strap Compulsory
 Geberit Cutting tools
Hi Visual Vest Compulsory
 Geberit Butt welding machine
 Ritmo Butt Welding plant Safety Boots Compulsory
 Spirit level Gloves Compulsory
 Measuring tape
 Plumb bob Eye Protection Compulsory
 Motor grinder Dust Masks & Coverall Compulsory
 Hand vacuum pump YES.
 Hand drill Safety Harnesses Fall Restraint
 Hand tools Only
6
 Concrete Chute
 Portable pump
 Calibrated pressure gauge
Project Hierarchy for Health and Safety Persons Responsible for First Aid
Mr. D. M Thilakarathne (MK) Tel: 0713850115 HKN Safety Officer

Sub-Con Safety
Mr. S. Meril (DJ) Tel: 0718296294
Officer
Mr. Mohomed Mufaric (FG) Tel: 0775181539
Mr.Senaka 0718074325
HSE Safety Mr. Hemachandra Tel: 0779740737 Mr.Upali 0717173817
Officer Mr. Lal Tel: 0712304774
HKN HSE
Mr. Jaseem Tel: 0755677450
Engineer
Mr. S. H Kim (MK) Tel: 0774052343
Sub-Con Project
Mr. H. Jeong (DJ) Tel: 0778670571
Director
Mr. Sooriya Bandara (FG) Tel: 0773440361
(HKN) HSE
Mr. J.W. Lee Tel: 0773318710
Manager
Issue of Safety Training Documentation:
All certificates relevant to this task i.e. certificates of competence will be held in HKN site office for review
and audit.
Emergency Arrangements:
HKN Emergency contact No. 0114333999
HKN to provide a first aid room
HKN Qualified First Aider – First Aid Kits Site Office & Stores.
Comply with HKN Fire Safety Plan & Fire Prevention and Evacuation Procedures.
Designated vehicle to be used for emergencies shall be available at all times. Details shall be displayed on
notice boards in a legible manner.
Vehicle No:
PC 5787, Driver: Janaka (Mob: 071-901-0009) - Night
P.G 4454, Driver: Pradeep (Mob: 078-742-6266)
PE 0146, Driver: Lio (Mob: 077-433-3684)
Access & Egress:
Site: Pedestrian and site walkways controlled by HKN. HKN will maintain proper access and egress at all
time.
Access Lighting (safety lighting):

Access lighting is to be provided and controlled by HKN, all access routes will be assessed for lighting prior
to carrying out works.
Task Lighting:
All task lighting will be supplied and maintained by subcontractor and used by subcontractor operatives.
The bulbs will be covered suitably against the direct emitting rays.
Hazardous Materials and Substances:

Name Number Status
CoSHH of ZRC Cold Galvanizing Compound HKN-COSHH-ME-0015 Status A
CoSHH of Sealant acetate white 310ML HKN-COSHH-ME-0002 Status A
CoSHH of Water Stop RX-101 HKN-COSHH-CN-0040 Status A
CoSHH of Mapefil GP HKN-COSHH-CN-0004 Status A
CoSHH of Portland cement HKN-COSHH-CN-0001 Status A
Waste Management:
Site: Waste materials will be placed in skips provided by HKN.
HKN will manage and control the disposal of all waste products/ material accordingly
HKN will dispose hazardous waste accordingly.
7
Special Control Measures:

No work shall be undertaken until Method Statement and drawings are approved
All operatives will have undergone HKN’s relevant inductions required to work in this area.
All operatives will be fully briefed on the Method Statement to comply for this operation.
All Operatives shall receive a daily briefing of works to be carried out before works commence.
All operatives will read, acknowledge and sign this Method Statement before commencing work.
Only trained (Qualified) operatives will move or operate plant.
Working at Height Considerations:

All scaffolding will be erected by subcontractor’s scaffolders in compliance with MST for scaffolding system
HKN-MST-CN-0084.
Welfare Facilities:
All Welfare facilities i.e. toilets, changing rooms and resting/eating areas will be provided and controlled by
HKN.
Smoking: Designated areas only. Ref Site Logistics plan HKN-PLN-CN-0001
Emergency Measures:
HKN will ensure that for all operations there will be an exclusion zone constructed with warning signs
displayed around working area where practicable.
Emergency Response Procedure HKN-PRC-HS-0002
Note: Following requirements should be achieved prior to starting the site works.
 All the materials should be approved.

 All the relevant shop drawings should be approved.
 All the CoSHH assessments should be approved.
 Subcontractor’s HSE officers and qualified scaffolders list will be submitted.
 HSE supervision & overall site coordination and control shall be carried out by HKN
until subcontractors deploy HSE manpower.
 The manpower required can be changed/ updated as per the actual stage of
construction phase.
Hhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhh
hhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhh
8
Responsibilities
HKN Sub-Contractor
 Plan construction activity according to approved

construction schedule. (Master plan)
 Evaluate necessary resources (Material, labour, tool
 Responsible for all construction activities ensuring & machinery, technical support, etc…) as per site
that all approved materials, shop drawing, method requirement.
statement and approved procedures are  Implement necessary safety measures as per site
Construction implemented and required approved permits are requirement.
Manager obtained from site authority.  Implement necessary quality control procedures as
 Facilitate construction staff. per site requirements.
 Coordinate with necessary department in  Determine necessary scaffolding/mobile scaffolding
construction site. arrangements by coordinating with site engineer
 Ensures that the site engineer/ supervisor and safety
officer has sufficient resources to complete the works
correctly & safely.
 Arrange resources as per the schedule.

 Arrange suitable storage for materials, store materials
as recommended by manufacturer and take material
preservation procedures.
 Identify suitable transportation method and arrange
facilities accordingly.
 Coordinate with sub-contractor and consultant.
 Arrange necessary training program coordinated with
 Monitoring site installations.
manufacturer and share the knowledge with site staff.
 Arrange necessary approvals.
Site Engineer  Arrange necessary mockup installations to meet
 Arrange temporary protection. quality parameters.
 Continuous supervision and monitoring of  Educate technical staff.
material/system installed
 Coordinate with main contractor.
 Coordinate with other sub-contractor.
 Coordinate with QA/QC engineer.
 Ensures that the Supervisor can complete the said
works by providing the appropriate instruction &
direction to complete the said works correctly & safely
 Material inspection.
 Inspecting material storage condition.
 Attending and verification of site inspection.
 Conduct surveillance and inspection duties at  Monitoring correct application of tools and
various stages to ensure compliance to the equipment’s.
QA/QC
approved QA/QC plan and the approved method  Check the quality of temporary protection.
engineer
statement.  Preparation of inspection and quality check list.
 Maintain quality records.
 Checking and verification of the workmanship.
 Examine and verify the quality of workmanship of
labour.
 Verify the datum lines and grid lines marked on site with
 Mark the necessary grid lines and datum lines on HKN surveyor.
Surveyor site.  Take necessary measurements from grid lines and
 Maintain necessary site records. datum lines and make necessary marking for site
installation.
9
 Execute the construction schedule/plan provided by

the site engineer according to the approved shop
drawing & method statement.
 Arrange necessary scaffolding, task lightning,
working spaces, and access and
barricades/storage/site cleanliness.
 Conduct toolbox meeting and explain daily plan to the
Supervisor
labourers.
 Before the start of site work check the physical
conditions of the labor.
 Coordination with HSE officer.
 Maintain portable first aid box.
 Ensures constant supervision & control of his workers
to complete the works correctly & safely
 Representative of Safety dept.

 Managing the development, maintenance and
implementation of HSE manual and procedures
under the leadership of the site HSE
 Assisting and reporting performance to the HKN
Project director on all HSE Matters.
 Overseeing environmental activities to ensure
compliance with laws and regulations and other
relevant requirements.
 Managing the HSE organization at the site.
 Establishment and updating of Project HSE Plan,
Management Program,
 Managing permit to work system, Risk
assessment of critical activities
 Investigating accident, incidents, near misses and
actions taken to avoid recurrences.
HSE Manager
 Carrying out the HSE Meeting, Audit and
Promoting for HSE improvement.
 Preparedness of Emergency Plan and Conduct of
Emergency Response Drill.
 Ensuring that adequate inspections and reporting
on working places and practices are carried out.
 Managing HSE records and documents.
 Promoting HSE awareness and competence
training at all levels.
 Stopping any activity on site in case of immediate
risk of injury or possibility of an accident.
 Liaising with the Head Office HSE team.
 Preparing HSE Management review report at least
once a year.
 Monitoring and verifying closeout of actions
arising from HSE audits.
10
 Make sure to arrange the safety induction program for

 Monitoring Tool Box Talk
all the workers
 Monitoring the implementation of the HSE
 Provide all necessary PPE.
Management System in assigned area
 Carryout necessary safety program and train all
 Collaborate with Supervisors in assessing
workers for all necessary safety measures.
training needs for personnel in the assigned
 Check work permit.
area
 Check the electrical appliances with electrician.
 Reports HSE findings to the relevant
construction personnel as well as the HSEM,  Check colour code and tags.
and follow-up  Ensures that there is adequate onsite supervision
HSE Officer  the status of implementation of the identified provided by the construction supervisor and the
preventive and corrective actions construction manager.
 Stopping Requires HSEM / HSE officer if  Ensure that all hazards in working area are properly
deemed unsafe. secured and warning signs have been placed
adequately when required.
 Site inspection / Electrical Inspection.
 Ensure good housekeeping practices.
 Fire prevention
 Ensure that daily checks have been carried out by the
 Equipment Inspection
respective operators and documented in correct
 Inspection of power tool (condition, cables and
format and kept those forms in correct place/s.
guards only)
 Ensure that chemicals/substances are stored as per
 Hot work inspections
the HKN H&S Plan and workers are adhering.
 Install and maintain wiring, control, and lighting

systems
 Check electrical components regularly
Electrician  Identify electrical problems with a variety of testing
devices
 Repair or replace wiring, equipment, or fixtures using
hand tools and power tools
 Carryout fabricator work as per approved shop

drawing/fabrication drawing and approved method
statement.
Plumber(fitter)  Maintain all necessary plant/tools and equipment
etc… in proper working condition and workshop
 Carryout the onsite installation as per approved shop
drawing
 Receiving and issuing the material.

 Carry out material inspection
 If there are any damages inform QC Engineer to take
necessary action.
 When receiving goods store keeper has to check the
Store Keeper condition and the damages. If they are in good
condition has to store them in a safe place and free
from damages.
 Keep necessary records
 Stores not to house flammable liquids or harmful
chemicals.
11
 The HKN Senior Scaffolding Supervisor will report

to the Senior Project Manager and will liaise with
the HKN HSE manager
 The Senior Scaffolding Supervisor will liaise with
the Construction Managers to establish the
scaffolds required and arrange the procurement
Senior and delivery of suitable materials.
Scaffolding  The Senior Scaffolding Supervisor shall ensure
Supervisor that procedures for safe working on scaffolding
during erection and dismantling are followed by
HKN and sub-con staff at all times.
 The Senior Scaffolding Supervisor shall make
sure that all scaffolding workers are suitably
qualified/ experienced to carry out their tasks.
 Train and assist all trainees deployed under him.
 All scaffolding inspectors (Sub-con) shall report to

Supervisor.
 Carry out regular checks on scaffolding to ensure
that the SCAFFTAG system is implemented
effectively.
Scaffolding  Carry out tagging of scaffolding in accordance with
supervisor the SCAFFTAG system when Inspectors are not
available.
 Train and assist all trainees deployed under him
 Senior scaffolder with more than 3 years active

experience will be appointed to this post.
 Work and follow advice and instructions from HKN
Scaffolding Supervisor.
 Checking scaffold on daily basis before workman
gets on to the scaffold, for any observable damages
and shifting or movement in scaffold assemblies.
Scaffolding  Scaffolding Inspector will implement the scaffolding
Inspector tagging system.
 Checking all long term scaffolds once a week and
grading by SCAFFTAG tagging.
 Checking that appropriate documentation is in
place
 Follow up the work of the scaffolding erectors under
their own foreman and instruct any safety related
issues.
 Personnel with a minimum of one year active
experience in scaffolding work will be deployed and will
carry certificates of competence from local training
schools.
Scaffolder  Erection of scaffolding, dismantling, adjusting and
repairing when required, under the supervision of
Inspector
 Attending safety meeting and tool box meetings to be
held daily at site before commencement of days’ work
 Follow site supervisor’s instruction to carryout daily

Skilled and works.
Un skilled  Unskilled workers shall be assigned under the direct
workers supervision of supervisor or skilled worker and not be
employed or assigned as skilled worker.
12
SECTION 2: DESCRIPTION OF WORK

2.1. Purpose
Purpose of this method statement is to carry out work activity as described under the
section of “Scope of work” and also includes the inspection plan. However more specific
details are included in respective shop drawings.
This method statement describes the Installation of HDPE Pipe Extension from Retaining
Wall to external Manhole for Waste and Rain Water Pipe network in Waterfront Integrated
Resort project, Colombo, Sri Lanka.
2.2. Scope of Work

Scope of this method statement includes the Installation of HDPE Pipe Extension and
connection to External Manhole.
 Installation of underground HDPE pipe
 Installation of HDPE pipes inside the Man hole.
 Puddle flange fixing on Retaining wall box opening
 Pipe fixing on Manhole box opening
 Leak testing for GEBERIT HDPE pipes
 Pressure testing for AGRU HDPE pressure pipes
Note – Installation of Corrugated PP pipe connection to the Manhole is included in HKN-MST-
ME-0037.
2.3. System Description
Waste and Rain water pipes coming through the buildings (GEBERIT HDPE pipes) and
Waste and Rain water pipes coming from the waste and rain water pumping pits (AGRU
HDPE pressure pipes) are passed through Retaining wall and connected to External
manhole.
This method statement is focused on HDPE pipe installation in between retaining wall and
the Manhole and HDPE pipe installation inside the Manhole which is illustrated in Sketch
3.3.a.
13
Sketch 3.3.a – HDPE pipe extension to external manhole
Sketch 3.3.b – Section A – A
14
2.4. List of Materials

Table 2.4 - List of materials
Material MSB Ref. Status Uses

Geberit High Density Polyethylene
1. HKN-MSB-ME-0032 A System pipes
(HDPE) pipe and fittings
2. Hangers and Supports HKN-MSB-ME-0137 A Pipe supports
Fixing accessories for mechanical HKN-MSB-ME-0223 -
3. A Hangers & Supports
services SUP-4
4. Mapefill GP HKN-MSB-CN-0023 A Grouting material
5. Portland cement HKN-MST-CN-0157 A For concreting works
For apply cut ends of
6. ZRC cold galvanized compound HKN-MSB-ME-0190 A
threaded rods
7. Konex Puddle Flange HKN-MSB-ME-0031 A Pipe installation
For stop water leakage
Underground drainage in manhole pipe
8. work (Expanding concrete HKN-MSB-ME-0009 A connection and
joint water stop) retaining wall puddle
flange outlet
AGRU High Density Polyethylene
9. (HDPE) pressure pipes and HKN-MSB-ME-0061 A Pressure pipes
Fittings
2.5. Material Storage

 The materials shall be unloaded and will be stored in UDA land. Subcontractors will
provide necessary storage.
 Before HDPE pipes are placed into storage, they should be visually inspected for
scratches, discoloration and other defects. Materials with cracks or defects shall be
sprayed with red paint to identify from the stock and stored separately.
 In storage area the pipes will be arranged on wooden pallet on the floor.
 The pipes shall be separated according to the sizes.
 Adequate storage space will be prepared and arranged in the most orderly manner
possible in order to place and remove materials.
 The storage area shall be provided with adequate protection against physical
damage to components. The storage area will have a relatively smooth, level
surface free of stones, free from debris or other materials that could cause to
damage the pipes.
15
 Stored material shall be closely monitored on a regular basis.

 Once pipes are taken on the site, those pipes will be stored safely until it is
installed in the correct location.
 Close supervision should be carried out to monitor good condition of the material is
maintained at all times.
2.6. Key Plan of Installation

HDPE Pipe extension and connection to external Manhole shall be installed in project wide as
shown in below given key plan.
Sketch 2.6 - Key plan of installation
16
2.7. Work Quality Flow Chart

Approved Documents
(Material submissions)
Material brought to
the site
Not approved
Inspection Reject Material
Approved
Store material
Pass
Setting-out if
required Fail
Material quality check
by QC Engineer
Reject Material
Shoring if required
Pass
Excavation Check and verify all the SPD, COSHH and MST are approved Resubmit and gain
approval
Compacting Site setting-out
Not approved
Leveling Concrete Pass Fail

bedding Check by QC Engineer Redo setting-out
Inspection
Pipe Fabrication
Approved
Repair & Pipe installation
Concrete bed lying Adjustm
Pass
Not Check by QC engineer
approved Repair & Adjustment
Manhole
construction
Inspection Testing
Approved
Check by QC Fail Repair & Adjustment
Puddle flange and pipe fixing in box opening Engineer
Pass
Approved
Appling Approved Not approved
concrete cover Inspection Repair & Adjustment
First stage Backfilling Warning and identification tape

laying
Approved Not approved

Second stage backfilling Inspection Repair & Adjustment
By Civil Department (Details are

included in HKN-MST-CN-0097)
Documents to be approved prior to proceed work. (MSB, MST, CoSHH, SPD)

Note: NCR will be issued when observed deficiency of the work and necessary
17
2.8. Method Statement Submission Plan

MST Submission Plan Waste and Rain Water System (Drainage System)
No MST No. MST Name Description Scop Approval Rev. No.
Conventional System
[*U/G Fully Embedded -Lesso HDPE *Man Hole & Trenches
3.1111
*Geberit HDPE & Accessories *Man Hole & Trenches *Pipe
Supports -Diamond Walraven ]
Sovent System
[*Geberit Silence db System*Geberit HDPE & Accessories *Pipe 3.111.2
Installation of Drainage pipe network Supports (Diamond Walraven) *Installation & Onsite Tests ]
building 1,3
HKN-MST-ME-0019 [WR 1] Pluvia Siphonic - Piping Status A Rev C
Installation of Drainage Pipe Network for 3.1.2.1.1
1 HKN-MST-ME-0020 [WR 2] [*GEBERIT Pipes & Acc *Installation and Onsite Testing] Status A Rev C
Building 4,5 & 6
HKN-MST-ME-0023 [WR 3] Above Ground (Roof BD 4,5 & Landscape) piping Status A Rev B
3.1.2.2.1.1
Method Statement for Installation of [*GEBERIT HDPE Pipes & Accessories *Onsite Testing]
Drainage Pipe Network for Building 02
Oil water - Piping
[*GEBERIT-HDPE up to sand box *LESSO HDPE Sand boxes to Oil 3.1.3.1
Separator *Pipe Installation & Accessories *Onsite Testing ]
Grease Water (Kitchen) Up to 1st GS - piping

[*Pipe Installation & Accessories *Leak Testing *Grease
3.1.4.1
Separator-Installation and Onsite Testing *Grease Separator-Final
Testing & Commissioning
Method Statement for Installation of ACO

HKN-MST-ME-0041 [WR 4] Car Park Floor Gully for Building 01 & 03 Oil water Gully Status A Rev A
2 3.1.5.1
HKN-MST-ME-0033 [WR 5] Installation of ACO Car Park Floor Gully for [*ACO Floor Gully *Onsite Testing ] Status A Rev B
Buildings 04, 05 & 06
Pluvia outlet
3 HKN-MST-ME-0028 [WR 6] Installation of Geberit Pluvia Rain Water 3.1.2.1.2 Status B Rev C
[*Pluvia Roof Outlet *Installation and Onsite Testing]
Drainage System for Building 4,5 & 6
Hume Pipes
Installation of Hume Pipe of Storm Water [*Installation and Leak Test*Manhole to manhole connection
4 HKN-MST-ME-0046 [WR 7] 3.2.2.2 Provisional Rev E
System for External Services. *Final connection of Manhole to Beira lake*Onsite Testing]
Installation of External Perforated Pipe for Under Ground RW Perforated pipe

5 HKN-MST-ME-0034 [WR 8] 3.1.2.2.1.3 Status B Rev D
Building 02 [*PAIPUTECH- Perforated uPVC pipes & Acc.]
Installation of Internal component and Oill Separator

6 HKN-MST-ME-0013 [WR 9] apply coating of oil separator in building [*Oil Separator-Installation *Oil Separator-Coting *Oil 3.1.3.2 Status A Rev F
1,3,4,5 & 6 Separator-Onsite Testing]
PP pipes (Corrugated)
PP Pipe Installation for External Waste [*Manhole to manhole connection *Expanding concrete joint
7 HKN-MST-ME-0037 [WR 10] 3.2.2.1 Status B Rev E
Pipe Network. water stop *Final connection of MH to Beira Lake *Pipe installation
and Accessories*Onsite Testing]
Sewer, Waste Water (Ex. M.H to City Main) - Piping System

External under ground Sewer, Waste
8 HKN-MST-ME-0311 [WR 11] [*Final connection to city main *Pipe installation & 3.2.1.1 To be submitted
Water system
Accessories *Onsite testing]
Sewer, Waste Water (Up to 1st Ex. M.H) - Pumping Pit &
Accessories
3.1.1.2
[*Pumps & Accessories *Agru HDPE Pressure Pipe *Electrical
Power & Control *Pressure Test]
Conventional R.W system - Pumping Pit & Accessories

[*Pumps & Accessories *Agru HDPE Pressure Pipe *Electrical 3.1.2.2.2
9 HKN-MST-ME-0054 [WR 13] Pumping Pit & Accessories Installation Status C Rev A
Power & Control *Pressure Test]
Sewer, Waste Water (Ex. M.H to City Main) - Pumping Pit &
Accessories
3.2.1.2
[*Pumps & Accessories *Agru HDPE Pressure Pipe *Electrical
Power & Control *Pressure Test ]
Grease Separator-Installation
10 HKN-MST-ME-0055 [WR 14] Grease Separator-Installation 3.1.4.2 For Approval Rev B
[*Grease Separator-Installation *Onsite Testing]
HDPE pipes (Corrugated)

HDPE Pipe Installation for External Rain
11 HKN-MST-ME-0056 [WR 15] [*Manhole to manhole connection *Final connection of MH 3.2.2.3 Status B Rev B
Water Pipe Network.
to Beira Lake *Pipe installation and Accessories*Onsite Testing]
Sewer, Waste Water (Up to 1st Ex. M.H) - Final Testing & Com. 3.1.1.4
Conventional R.W system - Final Testing & Com. 3.1.2.2.1.4
Oil separator - Final Testing & Commissioning 3.1.3.3

12 HKN-MST-ME-0316 [WR 16] Final Testing & Commissioning To be submitted
Grease Water (Kitchen) Up to 1st GS - Testing & Commissioning 3.1.4.3
Sewer, Waste Water (Ex. M.H to City Main) - Final Testing & Com 3.2.1.4
Rain Water (Ex MH to Beira Lk) - Final Testing & Com. 3.2.2.4
13 HKN-MST-ME-0022 [WR17] Retaining wall penetration detail Retaining wall penetration detail 3.2.3 Status A Rev D
Sewer, Waste Water (Up to 1st Ex. M.H) - Electrical Conduit
3.1.1.3
Installation for Waste & Rainwater Pumping Pit
Electrical Conduit Installation for Waste &
Conventional R.W system - Electrical Conduit Installation for
14 HKN-MST-ME-0027 [ WR 18] Rainwater Pumping Pit 3.1.2.2.3 Status B Rev B
Waste & Rainwater Pumping Pit
Sewer, Waste Water (Ex. M.H to City Main) - Electrical Conduit
3.2.1.3
Installation for Waste & Rainwater Pumping Pit
Marking and Identification for Waste and

HKN-MST-ME-0319
15 Rain Water Pipe Works Excluding Valves Marking and Identification 3.3 For Approval Rev B
[WR19]
and Equipment
HKN-MST-ME-0320 PP pipes installation of external rain *Manhole to manhole connection *Expanding concrete joint
16 [WR20] water pipe network water stop *Pipe installation and Accessories 3.2.2.1 5 For Approval Rev A
HDPE pipe extension from retaining wall

HKN-MST-ME-0321
to external manhale for Waste and Rain HDPE pipe extension from retaining wall to external manhale
17 [WR21] 3.2.4 For Approval Rev D
Water Pipe Network
ACO Floor Gully Installation of Buildings Above Ground (BD 4,5 & 6) Gully
18 HKN-MST-ME-0322 [WR 22] 3.1.5.2 For Approval Rev B
04, 05 & 06 [*ACO Floor Gully installation]
ACO Floor Gully Installation of Buildings Above Ground (BD 1,2& 3) Gully
19 HKN-MST-ME-0323 [WR 23] 3.1.5.3 For Approval Rev B
01, 02 & 03 [*ACO Floor Gully installation]
20 HKN-MST-ME-0324 [WR 24] GEBERIT Floor Drain Installation Geberit Floor Gully installation 3.1.5.4 For Approval Rev D
18
System breakdown of Waste and Rain Water System (Drainage System)
3.1.1.1.1 Conventional System [HKN-MST-ME-0019 / 20 / 23] [ WR 1/2/3]

[*U/G Fully Embedded -Lesso HDPE *Man Hole & Trenches *Geberit HDPE & Accessories *Man Hole & Trenches *Pipe Supports -Diamond
3.1.1.1 Walraven ]
Piping System
3.1.1.1.2 Sovent System [HKN-MST-ME-0019 / 20 / 23] [ WR 1/2/3]
3.1.1 [*Geberit Silence db System*Geberit HDPE & Accessories *Pipe Supports (Diamond Walraven)*Installation & Onsite Tests ]
Sewer, Waste 3.1.1.2 Pumping Pit & Accessories [HKN-MST-ME-0054] [ WR 13]
Water [*Pumps & Accessories *Agru HDPE Pressure Pipe *Electrical Power & Control *Pressure Test]
(Up to 1st
Ex.M.H) 3.1.1.3 Electrical Conduit Installation for Waste & Rainwater Pumping Pit[HKN-MST-ME-0027] [ WR 18]
3.1.1.4 Final Testing & Com. [ WR 16]

3.1.2.1.1 Piping [HKN-MST-ME-0019/20/23] [ WR1/2/3]
3.1.2.1 Pluvia Siphonic (Podium:BD4,5,6 & Roof BD 6) [*GEBERIT Pipes & Acc.*Installation and Onsite Testing]
[*Pluvia Roof Outlet *GEBERIT Pipes & Acc.*Installation and Onsite Testing] 3.1.2.1.2 Pluvia outlet [HKN-MST-ME-0028] [ WR 6]
[*Pluvia Roof Outlet *Installation and Onsite Testing]
3.1.2.2.1.1 Above Ground (Roof BD 4,5 & Landscape) piping

[HKN-MST-ME-0019 / 20 / 23] [ WR 1/2/3][*GEBERIT HDPE Pipes & Accessories *Onsite Testing]
3.1.2.2.1.2 Above Ground ( BD 4,5 & 6) Gully [ WR 12]

3.1.2
3.1.2.2.1 [*ACO Floor Gully installation]
Rain Water
(Up to 1st Ex. Piping System 3.1.2.2.1.3 Under Ground RW Perforated pipe [HKN-MST-ME-0034] [ WR 8]
M.H) [*PAIPUTECH- Perforated uPVC pipes & Acc.]
3.1.2.2
Conventional 3.1.2.2.1.4 Final Testing & Com. [ WR 16]
R.W. System
3.1.2.2.2 Pumping Pit & Accessories [HKN-MST-ME-0054] [ WR 13]
[*Pumps & Accessories *Agru HDPE Pressure Pipe *Electrical Power & Control *Pressure Test]
3.1.2.2.3 Electrical Conduit Installation for Waste & Rainwater Pumping

3.1
Pit[HKN-MST-ME-0027] [ WR 18]
Inside
Buildings 3.1.3.1 Piping [HKN-MST-ME-0019 / 20 / 23] [ WR 1/2/3]
[*GEBERIT-HDPE up to sand box *LESSO HDPE Sand boxes to Oil Separator *Pipe Installation & Accessories*
Onsite Testing ]
3.1.3
Oil Water 3.1.3.2 Oill Separator [HKN-MST-ME-0013] [ WR 9] To Rain
Water
[*Oil Separator-Installation *Oil Separator-Coting *Oil Separator-Onsite Testing] System
3.1.3.3 Final Testing & Commissioning [ WR 16]
3.1.4.1 piping [HKN-MST-ME-0019 / 20 / 23] [ WR 1/2/3]

[*Pipe Installation & Accessories *Leak Testing *Grease Separator-Installation and Onsite testing
3.1.4
Grease Water 3.1.4.2 Grease Separator-Installation HKN-MST-ME-0055 [ WR 14]
To Sewer and
(Kitchen) Up [*Grease Separator-Installation *Onsite Testing Waste Water
to 1st GS) System
3.1.4.3 Testing & Commissioning [ WR 16]
3.1.5.1 ACO car park gully

[HKN-MST-ME-0041/ 33] [ WR 4/5]
3.1.5 3.1.5.2 ACO Floor Gully of Buildings 04, 05 & 06 [WR 22]
waste & rain
water gully
installaion 3.1.5.3 ACO Floor Gully of Buildings 01, 02 & 03 [WR 23]
3.1.5.4 GEBERIT Floor Drain [WR 24]
3.2.1.1 Piping System [ WR 11]

[*Final connection to city main *Pipe installation & Accessories *Onsite testing]
3 3.2.1 3.2.1.2 Pumping Pit & Accessories [HKN-MST-ME-0054] [ WR 13]
Waste & Sewer, Waste [*Pumps & Accessories *Agru HDPE Pressure Pipe *Electrical Power & Control *Pressure Test ]
Water
Rain water
(Ex. M.H to
system 3.2.1.3 Electrical Conduit Installation for Waste & Rainwater Pumping Pit[HKN-MST-ME-0027] [ WR 18]
City Main)
3.2.1.4 Final Testing & Com [ WR 16]
3.2.2.1 PP Pipe Installation for External Waste Pipe Network [HKN-MST-ME-0037] [ WR 10]
[*Manhole to manhole connection *Expanding concrete joint water stop *Final connection of MH to Beira
Lake *Pipe installation and Accessories*Onsite Testing]
3.2.2.2 Hume Pipes [HKN-MST-ME-0046] [ WR 7]

3.2.2 [*Installation and Leak Test *Manhole to manhole connection *Final connection of Manhole to Beira lake *Onsite Testing]
Rain Water
(Ex. M.H to Beira 3.2.2.3 HDPE pipes [HKN-MST-ME-0056] [ WR 15]
Lk) [*Manhole to manhole connection *Final connection of MH to Beira Lake *Pipe installation and Accessories*Onsite Testing]
3.2
3.2.2.4 Final Testing & Com. [ WR 16]
External
3.2.2.5 PP pipes installation of external rain water pipe network [HKN-MST-ME-0320] [ WR 20]
[*Manhole to manhole connection *Expanding concrete joint water stop *Pipe installation and Accessories]
3.2.3 Retaining wall penetration detail [HKN-MST-ME-022] [WR 17]
3.2.4 HDPE pipe extension from retaining wall to external manhale [WR 21]
3.3 Marking & Identification [WR 19]
Note: Scope of this submission is marked on above MST Submission Plan
19
SECTION 3: INSTALLATION METHODOLOGY

This section describes step by step work sequence from on-site material inspection to
Installation of HDPE Pipe Extension and connection to External Manhole.
Note –
 Same Installation methodology is used for Waste and Rain water pipes coming
through the buildings (GEBERIT HDPE pipes) and Waste and Rain water pipes
coming from the waste and rain water pumping pits (AGRU HDPE pressure pipes).
 Leak test will be carried out only for the GEBERIT HDPE pipes and Pressure test
will be carried out only for the AGRU pressure pipes.
Sequence of Work
Inspect Material Setting Out Excavation Concrete Bedding Pipe fabrication Pipe
Installation Puddle Flange and pipe fixing in Box opening Testing Concrete encasement
…… Backfilling and Compaction
3.1. Inspect Material

 Material check will be carried out by Sub-Contractor & HKN QC engineer before
materials are used on site.
 Material inspection will be done by HKN and MIR will be raised for the engineer’s
inspection.
3.2. Setting Out

 All benchmark/ survey setting out point, gridline and datum lines will be marked by HKN
surveyor.
 HKN surveyor & sub-contractor surveyor will carry out joint inspection & verify all
survey points/survey references.
 Sub-contractor surveyor will mark final installation location on site based on survey
points/survey references provided by HKN surveyor as well as approved shop drawings.
 After location verification installation will be carried out.
3.3. Excavation Pipe Trenchers

 Shoring, Excavation, Backfilling & Compaction will be carried out by civil department as
per the HKN-MST-CN-0097 method statement.
Note: Soil bearing capacity will be checked after compaction when necessary. Requirement
should be ˃100kPa. If not soil improvement will be carried out as per the method statement
for external work. (HKN-MST-CN-0097).
20
3.4. Concrete Bedding
 Concrete bedding will be carried out according to the approved shop drawings on
already excavated areas.
 50 mm lean concrete will be applied prior to pipe are installed.
 Concrete bed details are included in Sketch 3.3.b – Section A – A (Page 14).
3.5. Pipe fabrication
3.5.1 Pre fabrication

 Pre fabrication will be carried out as per approved shop drawings and fabrication
drawings by skilled plumber.
 Before the fabrication the materials will be ensured without any damages
 Pre fabrication will be done in temporary work shop Fabrication will include pipe
cutting, Butt welding pipe to pipe, fabrication of pipe with puddle flange (Refer Section
3.5.1.1 – Fabrication of HDPE pipe with puddle flange), pipe to fitting and connection of
fabricated pipe branches to other pipe and fittings.
 Pipe will be cut by using Geberit HDPE pipe cutting tools. [Refer section 3.5.1.2 –
Geberit Processing Tools (Page 22)].
 Geberit HDPE pipe Butt welding will be carried out using Geberit Butt welding machine
[Refer section 3.5.1.3 – Butt Welding (Page 28)].
 AGRU HDPE pressure pipe Butt welding will be carried out using Ritmo Butt welding
plant. [Refer section 3.5.1.4 – Butt Welding process of AGRU HDPE pressure pipes
(Page 31)].
 Welding will be carried out in good and safe environment condition. In case of damp
condition, additional protection shall be provided to cover the weld area.
 Initiate an internal inspection prior to start next activity.
3.5.1.1 Fabrication of HDPE pipe with puddle flange
21
Sketch 3.5.1.1 - Pipe insert with puddle flange
• Cut HDPE pipes using HDPE pipe cutting machine to required lengths as per the
approved shop drawing. (Refer : HKN-MSB-ME-0006,HKN-MSB-ME-0032,HKN-
MSB-ME-0061 and HKN-SPD-ME-PD_00903)
• Clean the surface of pipe thoroughly to remove all loose materials
• Place Konex Puddle flange around the center of pipe
• Fix Konex puddle collar for HDPE pipe by using elastomer with stainless steel
bands and locks on the HDPE pipe.
• Fix the temporary end caps to both ends (Wooden end cap will insert in to the pipe
ends and cover with duct tapes).
3.5.1. 2 Geberit Processing Tools
22
23
24
25
26
27
3.5.1.3 Butt Welding process of Geberit HDPE pipes
28
29
30
3.5.1.4 Butt Welding process of AGRU HDPE pressure pipes
31
32
33
34
35
36
3.5.2 On site fabrication

 On site fabrication will be carried out as per approved shop drawings by skilled plumber.
 On site fabrication will be done, where near to installation is to be carried out.
 On site fabrication will be included pipe cutting, socket fusion and butt welding pipe to
pipe, pipe to fitting and connection of pre-fabricated pipe branches to other pipe and
fittings.
 Pipe will be cut by using Geberit HDPE pipe cutting tools. Refer section 3.5.1.2 –
Geberit Processing Tools (Page 22).
 Geberit HDPE pipe Butt welding will be carried out using Geberit Butt welding machine.
Refer section 3.5.1.3 – Butt Welding process of Geberit HDPE pipes (Page 28).
(Page 31)].
 Welding will be carried out in good and safe environment condition. In case of damp
condition, additional protection shall be provided to cover the weld area.
 Initiate an internal check prior to start next activity.
3.6. Pipe Installation

Note – Before install the HDPE pipes, cleaning and preparing of box openings in retaining wall
and Manhole should be carried out according to the step 1 in Section 3.7.1 and section 3.7.2)
 Before installation of all pipes, fittings, etc., shall be cleaned inside and outside by
using cotton waste.
 Prior to install each pipes and fittings will be visually inspected for possible cracks or
defects. Materials with crack or defect will be sprayed with red paint to identify from the
stock and shall be removed immediately from the site.
 Pipe installation will be performed according to approved shop drawings. In case of
fouling or clashing of line with other pipe networks, structure, equipment, etc., the
matter will be brought to the HKN Engineer’s notice and corrective action will be taken
as per his instruction.
 Pipe will be cut by using Geberit HDPE pipe cutting tools. Refer section 3.5.1.2 –
Geberit Processing Tools (Page 22).
 Geberit HDPE pipe Butt welding will be carried out using Geberit Butt welding machine;
Refer section 3.5.1.3 – Butt Welding process of Geberit HDPE pipes (Page 28).
(Page 31)].
 After pipe installation process, initiate the inspection request for the pipe installation for
the Engineer’s approval prior to start next activity.
37
Note - Prior to install the HDPE pipes, pipe supports should be install.
3.6.1. Installation of pipe support for Underground HDPE pipes

 The relevant support size clamp and the anchor bolts will be selected according to the
approved shop drawing.
 The starting and end point of the pipe route will be marked on the concrete bed.Then a
nylon string will be placed between the marked start and end point of the pipe network
to indicate the proposed pipe route. The level of the nylon string will be indicated the
top of the pipe level. After that the alignment of the nylon string will be ensured.
 Correct support intervals will be selected according to the approved shop drawing.
 Pipe support installation points will be marked on the concrete bed.
 After the confirmation that the pipe route and the pipe support installation points are as
per the approved shop drawing, holes will be drilled for the installation of drop in
anchor. The holes will be drilled by marking the correct depth on the drill bit with a
permanent marker, to ensure the correct drilling depth of the holes. Dust and concrete
debris from the drills holes will be blown out by hand Vacum pump. The drop in anchor
will be pushed in to the drilled hole and then it will be punched into the holes by using
tool punch. Drop in anchor installation procedure is mentioned in Sketch 3.6.1.a - Drop
in anchor installation details, table 3.6.1 : drop in anchor instalation detail and Sketch
3.6.1.b - Drop in anchor installation procedure.
 Threaded rod will be measured and cut according to the required length. This threaded
rod will be cut by using motor grinder, at the ground level to increase the safety
awareness. The prepared threaded rod will be inserted into the already installed drop in
anchors and tighten accordingly by using suitable wrench and lock nut.
 Clamps will be fixed to the threaded rod suspension and locked in position by nuts and
washers.
Sketch 3.6.1.a - Drop in anchor installation details
38
Table 3.6.1: Drop in anchor installation details
Anchor size L (mm) HΦ (mm) Hd (mm)
M6 25 8 30
M8 30 10 32
M10 40 12 42
M12 50 15 53
M16 65 20 70
01. Drill a hole to the recommended diameter and depth. Clean the
hole thoroughly with a hole cleaning brush. Remove the debris
with a hand pump, compressed air, or vacuum.
02. Insert the anchor into the hole. Using a hammer and the
appropriate setting tool, drive the expansion plug into the
anchor until the shoulder of the tool rests against the surface of
the anchor.
03. Position the fixture, insert the bolt or threaded rod and tighten
with a suitable wrench.
Sketch 3.6.1.b - Drop in anchor installation procedure
3.6.2. Installation of pipe support for Vertical HDPE pipes inside the manhole
 Drop in anchors, threaded bar and Two Bolt clamps will be used for vertical pipe
installation inside the manhole.
 Suitable vertical intervals between two supports will be selected from approved shop
drawings.
 Highest point and the lowest point of the pipe route will be identified and marked on the
manhole wall. Plumb bob will be used to ensure the verticality.
 A plumb bob will be hanged on the highest point of the pipe route to indicate the
vertical path of the pipe routine.
 After the confirmation that the pipe route and the pipe support installation points are as
per the approved shop drawings, holes will be drilled for the installation of drop in
anchor {more details about the drilling refer sketch 3.6.1.a (Page 38 ) and table 3.6.1
(Page 39)}. The drop in anchor will be pushed in to the drilled hole and then it will be
fixed to the wall. Drop in anchor installation procedure is mentioned in sketch
3.6.1.b.(page 39).
39
 Threaded rod will be measured and cut to the required length. This threaded rod will be
cut by using motor grinder. The cut threaded rod will be inserted into the installed drop
in anchors and tightened by using suitable wrench and nut. Cut ends of threaded rod
will be coated with ZRC galvanized compound. Exposed area hangers and supports
will be painted as per the procedure indicated in the method statement for painting for
GI pipe fittings and supports of fire protection system.(HKN-MST-ME-0044).
 Two bolt clamps will be fixed to the threaded rod suspension and locked in position by
nuts and washers.
3.6.3. Installation of Underground HDPE pipes
Sketch 3.6.3 - Installation of pipe on Support
 Take pipe invert levels and dimension as approved shop drawing issued by HKN.
 Pipe will be selected as per approved material and approved shop drawings.
 Placed pipe at correct location based on setting out information. Threaded rod will be
used to fix pipe at correct location and maintain correct slope.
 Recheck pipe position and invert levels, pipe sizes, and pipe slope.
3.6.4. Installation of vertical HDPE pipes inside the Manhole

 The pipe will be hoisted vertically and placed in the clamps by tightening the nuts and
bolts. ( Refer Sketch 3.6.4 – Installation of Vertical Pipe)
 Vertical alignment will be checked and adjusted by tightening or losing the nuts and
washers.
40
Sketch 3.6.4 – Installation of Vertical Pipe

3.7. Puddle flange and pipe fixing in Box openings.
3.7.1. Puddle flange fixing in the retaining wall box opening

Note:-
- Puddle flange fixing in the retaining wall box opening will be carried out according
to the approved shop drawing HKN- SPD-ME-PD-00903.
- Step #1 should be carried out prior to pipe installation
Step # 1:
 Before fix the puddle flange on the Retaining wall box opening, the box
openings should be clean and Chip off surface with 45⁰ carve on top of the
retaining wall opening in order to make proper bonding with concrete. (Refer
Sketch 3.7.1.a – Retaining wall box opening preparing )
Sketch 3.7.1.a (Reference - HKN- SPD-ME-PD-00903)

41
Step # 2:
 Apply the water stop (RX-101) as shown in the Sketch 3.8.1.
Sketch 3.7.1.b (Reference - HKN- SPD-ME-PD-00903)

Step # 3:
 Install the formwork (Maintaining 45⁰ angle as shown in the Sketch 3.7.1.b)
with pipe openings for side “B” as shown in the Sketch 3.7.1.c
 Place HDPE pipe with Konex puddle flange at correct position using formwork
openings
 Install the formwork (Maintaining 45⁰ angle as shown in the Sketch 3.7.1.b)
with pipe openings for side “A” as shown in the Sketch 3.7.1.c
Sketch 3.7.1.c (Reference - HKN- SPD-ME-PD-00903)
42
Step # 4:
 Re check pipe position, levels and slope by using spirit level. (As shown in the
Sketch 3.7.1.d)
Sketch 3.7.1.d(Reference - HKN- SPD-ME-PD-00903)
Step # 5:
 Fill up the non-shrinkage grout in to the box opening from side “A” using
100mm formwork gap until fully fill up the opening. (As shown in the Sketch
3.7.1.e)
Sketch 3.7.1.e (Reference - HKN- SPD-ME-PD-00903)
43
Step # 6:
 Remove the formwork from both sides of the opening
 Chip off the non-shrinkage grout additional fill. (As shown in the Sketch 3.7.1.f)
Sketch 3.7.1.f (Reference - HKN- SPD-ME-PD-00903)
3.7.2. Pipe installation on Manhole box opening

Note:-
- Pipe installation on Manhole box opening will be carried out as per the approved
shop drawings (HKN-SPD-EX-PD-00900 A) which is further described in below
steps
- Step #1 should be carried out prior to pipe installation
Step # 1:
 Before fix the pipe in External Manhole box opening, the box openings should
be clean and Chip off surface in order to make proper bonding with concrete.
(Refer Sketch – 3.7.2.a – External Manhole box opening preparing).
44
Sketch 3.7.2.a
Step # 2:
 Apply the water stop (RX-101) as shown in the Sketch 3.7.2.b.
Sketch 3.7.2.b
Step # 3:
 Install the formwork with pipe openings for side “B” as shown in the Sketch
3.7.2.c
 Place HDPE pipe at correct position using formwork openings
 Install the formwork with pipe openings for side “A” as shown in the Sketch
3.7.2.c.
Sketch 3.7.2.c
45
Step # 4:
 Re check pipe position, levels and slope by using spirit level. (As shown in the
Sketch 3.7.2.d)
Sketch 3.7.2.d
Step # 5:
 Fill up the non-shrinkage grout in to the box opening from side “A” using
formwork gap until fully fill up the opening. (As shown in the Sketch 3.7.2.e)
Sketch 3.7.2.e
46
Step # 6:
 Remove the formwork from both sides of the opening
 Chip off the non-shrinkage grout additional fill. (As shown in the Sketch 3.7.2.f)
Sketch 3.7.2.f
47
3.8. Testing
3.8.1. Leak Test
Sketch 3.8.1 – Leak Testing
 Leak testing to be carried out only for GEBERIT HDPE pipes.

 Testing will be done for the whole pipe network from retaining wall to external manhole.
(Refer sketch 3.8.1 – Leak Testing).
 HDPE pipe ends will be covered temporary and apply silicon sealant except the pipe
openings and left for 2 hours’ for the silicon to cure.
 Temporary PVC pipes will be installed in the high end (Refer Sketch 3.8.1 – Leak
Testing) of HDPE pipe as per indicated in above sketch.
 HDPE pipe will be filled with water in one side, to allow the air inside the network to
escape from the other opening.
 Fill water in HDPE pipe to a minimum of 1m level of temporary PVC pipe, which will
apply pressure to the pipe network.
48
 After the water filling, the test will last for a minimum of 4 hours duration before
discharging water
 Water level should be monitored during above period
 Testing criteria are met if the maximum water level drop is less than 20mm (or in pre-
defined tolerance) and no water drop around the pipe joints.
 If the test fails, recheck the pipe joints.
 Identify the issue and proper corrective action has to be discussed with the QC
engineer / consultant engineer.
 Implement the corrective action and re-do leak test again.
 Initiate the inspection request for the leak test for the engineer’s approval prior to finish
the installation.
 After leak testing all water will be drained out and that segment of pipe work will be
kept empty. (without water)
 Flushing and drain water will be diverted to a temporary site drainage system as
necessary.
 Water is taken from temporary site water supply system which is fed by the city potable
water main.
3.8.2. Pressure Test

 Pressure testing to be carried out only for AGRU HDPE pressure pipes
 Pressure testing will be carried out for the whole pipe network from retaining wall to
external manhole prior to concreting process.
 Pressure test should be carried out with calibrated pressure gauge and test certificate
should be submitted with inspection check list when raising inspection request.
 Close all openings by using thread seal and test plug.
 Lowest point of the pipe network to be connected to the pressure pump.
 Fix the valve at highest point to release the air.
 Fill water in the pipe network and pressurize the system.
 The test pressure should not be less than 3.5 bar or 1.5 times the working pressure
which ever highest.
 Testing criteria are met if the pressure drop shall not be more than 20kpa, within 2
hours without leakage.
 If satisfied the test, water will be released from the lowest end in front of the consultant
engineer.
 If pressure test fails, identify & rectify the problem & redo the test until the testing is ok.
Note - Once the pressure test and inspection are completed, underground area will be handed
over to construction team to carry out concreting work
49
3.9. Concrete encasement

 After the Leak test or Pressure test is completed, applying concrete encase will be
carried out as per the approved shop drawings.
 Concrete encase details are included in Sketch – Section A-A (Page 14)
 After curing the concrete cover, backfilling operation will be carried out as per approved
shop drawings and as per Back Filling
 Backfilling and Compaction will be carried out as per the Back-filling and Compaction of
Substructure method statement (HKN-MST-CN-0097) by civil department.
 Warning and identification tapes with tracer wire will be laid after the first stage of
backfilling.
 Inspection request will be initiated for Engineers approval.
Note: Care should be taken to avoid any damages to the pipe during compaction.
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Page: 52/92 Method Statement for HDPE Pipe Extension from Retaining
Wall to External Manhole for Waste and Rain Water Pipe HKN-MST-ME-0321
Owner: HKN Network
SECTION 5: RISK ASSESSMENT

5.1 Detail Risk Assessment Sheet
5.1. RISK ASSESSMENT Risk Assessment Number: ME/0321 Date: 08-02-2019
Method Statement for HDPE Pipe Extension from Retaining Wall to External
Work Activity Rev. D
S/ Original risk rating Revised Risk Rating
Activity Hazard Involved Risk Mitigation Action Remarks
N P I V R P I V R
5.1.1 GENERIC RISK ASSESSMENT
1. Clear even access to be maintained in working

area.
 Slips, Trips 2. Works area to be maintained free from sudden
 Wet or dusty floors and Falls changes in level. Ensure rubbish, debris and
 Spillage of wet or  Injuries with materials stored correctly.
Site dry substances – oil, nail piercing 3. Provide appropriate access/egress points.
preparation water,  Impact on Adequate edge protection around the area
 Slippery floors steel or 4. Include regular cleaning program and
1. 3 4 12 Medium 1 2 2 Low
A. Access &  Wet weather sharp edges workplace inspections both during and before
Egress conditions resulting in and after shifts. Workplace procedures for
 Unsuitable footwear fatalities or cleaning up spills.
or sloping floors serious 5. Keeping work areas well maintained, clean,
 Poor Housekeeping injuries well lit, uncluttered and free of waste. Keeping
walkways clear of obstructions.
6. Storing materials and equipment neatly and
out of the way of construction activity area and
52
Owner: HKN Network
N P I V R P I V R
accesses. Regularly removing waste and
compliance with waste management
procedures.
 Electric 1. All power feeds, electrical, pneumatic or
 Inadequate
shock hydraulic, to comply with European or British
illumination/ poor
 Electric Standards and maintained in good condition
visibility
burns 2. Work in-charge shall be ensured adequate
 Overhead power line
 Electrical illumination and shall be coordinated with HSE
 Inadequate wiring,
fires and and electrician
B. Work place  Exposed electrical
explosions 3. ELCB shall be provided to all DBs’ - Proper
illumination parts
 Arcing cable management required
& Provision  Not maintaining
 Secondary 4. Provide proper earthling / grounding system
of safety device in 3 5 15 High 2 2 4 Low
hazards 5. Remove all cables with damaged insulation
temporary distribution panel
(broken and broken plugs
electricity (Residual current
bones 6. Provide competent and trained electrician for
device- RCD)
cardiac all electrical connection works
 Defective insulation
arrest 7. Disconnect the power source before servicing
 Poor or no earth
 cut and or repairing electrical equipment.
connection to
scrapes, 8. Servicing and installation must only be
distribution
property undertaken by a qualified electrician. Where
damage) ever possible work should be performed on a
53
Owner: HKN Network
N P I V R P I V R
dry insulated floor. Wooden platforms, rubber
mats, or dry areas provide extra protection
especially in confined spaces.
9. Lock-out/ Tag-out system shall be applied.
10. When handling / installing temp. electricity
ensure that power source is either off or
isolated
11. Trained operative and/or HSEO to assess the
amount of task lighting required.
 Accumulation of 1. Regular housekeeping to be ensured before
 Fatality
construction and and after work
 Burn
other waste lead to 2. Excessive and unnecessary material to be
 Property
fire ,slips and store in a proper way or removed from working
damage
tripping hazards area
C. Waste  Wrist
 Environmental 3. Scheduled (Mass) housekeeping for each
handling fracture 3 4 12 Medium 1 2 2 Low
Pollution building weekly basis
 Physical
 Attract flies, dogs 4. Worker and supervisory team shall be
pain
rats and other educated in a frequent basis by HSE team
 Biological
rodents 5. Chemical treatment practice shall be
 Viral or
continued to avoid the insects spreading
bacterial
6. Follow good housekeeping practices at
54
Owner: HKN Network
N P I V R P I V R
always
7. Waste materials should not be kept prolong in
work in work area and those wastes should be
transferred regular basis into the garbage/
waste collection location
8. Waste collecting skips should be covered at all
times and not to be overload
9. Regularly educate the employee about the
importance of practicing good housekeeping
and personal hygiene
1. All leading edges are to be covered by guard
rails and toe boards
 Falling from
2. Floor opening to be covered with steel net
height
 Falling material and/or fly wood sheet where applicable and
D. Edges and  Fatality
 Unsuitable floor appropriate
voids  Partial/
coverings or sloping 3 5 15 High 3. HSE team are to be monitor and take action 2 2 4 Low
protection permanent
floors, regularly
disability
4. Workers and supervisory team shall be
Physical
educated during TBTM
pain
5. Additional signage shall be displayed
wherever applicable i.e. do not step on
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Owner: HKN Network
N P I V R P I V R
 Mechanical  Entangleme 1. Conduct inspection on all power tools and
entanglement in nt of cloth or extension cables before starting the job
rotating spindles hair with 2. Where practicable only 230/240 v power tools
or sanding discs; moving parts to be used
 Waste material  Eye injury 3. Power tools shall be used by competent

from dust people
flying out of the
Operation of other minor 4. Do not use power tools without safety guards
cutting area
Work particles, or PPE
 Coming into
Equipment  Cut injury, 5. Loose clothing and long hair to be kept clear
contact with the
 Burn, of moving parts of power tools. Operatives
cutting blades or
2. A. Hand  Electrical 4 5 20 High shall be trained in the correct use of portable 2 2 4 Low
drill bits;
held shocks, tools
 Risk of hitting
power broken 6. Suitable eye protection to be worn where there
tools,
electrical, gas or is a foreseeable risk of eye injury. Suitable
bones,
water services cardiac PPE to be worn where there is a foreseeable
when drilling into arrest dust hazard
building surfaces  cuts and 7. Tools must be used in accordance with
 Poorly maintained, scrapes, manufacturer’s instructions. Qualified persons
tools and cables property will test all portable electrical equipment at
or cutting the damage) recommended regular intervals, i.e. offices 12
electrical cable  Hand-arm months, workshops 6 months and on-site 3
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Owner: HKN Network
N P I V R P I V R
 Manual handling vibration monthly intervals. Evidence of such test shall
 Hazard from be available
trailing cables, 8. Select power tools with lowest vibration level.
hoses or power A tool producing high levels of vibration to

have anti-vibration handles to reduce the risks
supplies
Hand/Arm Vibration Syndrome (HAVS) – see
 Flying particles
below. Minimize the time individuals use the
 Injury from poorly
equipment i.e. job rotation. Noise Assessment
secured or
required where deemed necessary
clamped work-
9. A safe working platform is required when
pieces
using a power tool (in preference to equipment
 Dust and fumes such as a step ladder).
given off during 10. No one is to work underneath raised platform
the use of the while power tools are being used
tools 11. Make sure the circuit is fitted with a GFCI
(currently all panel boards are fitted with
GFCI’s)
12. When manual handling always use the
appropriate safe lifting.
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Owner: HKN Network
N P I V R P I V R
 Inhalation 1. Specially protected and insulated tools for to
 Access: slips, trips
of be used
and falls;
dust/fume/ 2. Tools made of suitable quality materials
 Falling and
mist; lead to which will not chip or splay in normal use
moving objects;
lung 3. The correct tools for the job
 Obstructions and
B. None diseases in 4. Spanners not being used when jaws are
projections;
mechanic long term, sprung to the point that slippage occurs.
al  Lifting and
vomiting, 5. The regular inspection of hand tools to be
machiner handling;
irritation, ensured
y and  Electricity
skin allergic 6. Discarding or prompt repair of defective
Non- (including static 3 4 12 Medium 2 2 4 Low
 Shock, tools
power electricity):
burns 7. Taking time to keep tools in the proper
hand  Noise and
 Burns and condition and ready for use
tools vibration
other 8. Proper storage to prevent damage and
 pressure and
injuries corrosion
vacuum
from fire 9. Locking tools away when not in use to
 Suffocation
and prevent them being used by unauthorized
 Radiation: ionising
explosion; people
and non-ionising;
 Musculoske 10. Serrated jaws provide sure gripping action
 Biological: viral or
letal when pulling or twisting wires
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Owner: HKN Network
N P I V R P I V R
bacterial disorders
 Human errors  Mental
 Physiological overload/
effects under load
 Psycho-
physiological
effects
 Hazards from the
environment
where the
machine is used
 Lifting a load  Back injury 1. Lift load should be assessed and confirmed
which is too heavy  Muscular 2. All operatives shall be given frequent and pre-
Lifting
or too sprains and training before place them for operation about
operations
cumbersome strains safe lifting techniques and about the load
3.  Poor posture  Foot injury 4 3 12 Medium 3. Appropriate PPE shall be worn 2 2 4 Low
A. Manual
during lifting or  Trapped 4. Movement of manual handling shall be
Handling
poor lifting  Hand injury minimized
technique  Nerve 5. Physical fit personal only allow for manual
 Dropping a load  Hernia handling operation
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Owner: HKN Network
N P I V R P I V R
 Lifting sharp-  Cuts 6. Repetitive movement shall be minimized
edged or hot loads  Fractures through frequent breaks
7. Lifting path shall be cleared and free from
obstructions
 Incorrect use, 1. Operator shall be fit and competent to operate
 Overturning 2. A safe system of work in place
 Insecure, 3. No persons allowed under suspended load

 Back injury 4. A regular maintenance schedule shall be
excessive or
 Muscular followed for the equipment
uneven loading
sprains and 5. Areas must be barricaded / signed.
B. Manually  Incorrect tilt
strains 6. Follow approved method statement and risk
operated  Driving along a
 Foot injury assessment
load ramp
 Trapped 3 4 12 Medium 7. sufficient room shall be available to easily 2 2 4 Low
handling  Overloading –
 Hand injury maneuver the equipment
equipment exceeding the
 Nerve 8. Certified and inspected equipment used for
rated capacity of
 Hernia the operation
the
 Cuts 9. Adequate visibility and lighting available
 Machine collisions
 Fractures 10. Weather conditions shall be monitored by in-
 Presence; uneven charge foreman or Engineer and work
road surface stopped when necessary – particularly when
 musculoskeletal wind speed exceeds allowable limits or during
60
Owner: HKN Network
N P I V R P I V R
problems for thunderstorms
 The driver;
 Overhead
obstructions
1. Use only trained competent, skilled
operatives.
2. Ensure all workers are trained and competent
 Sprains to do the work
C. Mechanic
and strains 3. Unload members from trailers as close as
ally
 Slips trips possible to work area
operated  Maneuvering
falls 4. Unloading area must be in designated areas
load  Speed
 Collide with that do not restrict other vehicle movements
handling  Blind spot
people and 3 5 15 High 5. Obey speed limits and warning signs. Drive at 2 2 4 Low
equipmen  Load stability
vehicle speeds suitable to the road surfaces and
t  Fueling
 Fatal injury traffic conditions
 Serious 6. When travelling, fork arms should be just
i). Forklift below axle level but must be kept clear of the
physical
hazards road/floor surface
7. Workplace environment checks
8. Pre-operational forklift checks
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Owner: HKN Network
N P I V R P I V R
1. Only competent trained scaffolders to erect or
dismantle scaffolds.
2. Only competent trained inspectors to inspect
and sign scafftags (weekly basis)
 Incompetent 3. No workers to be allowed to work underneath
persons are scaffolds being erected.

 Falling from 4. Barriers around work area to be erected
erecting scaffolds.
height 5. During erection and dismantling a red scafftag
Not using selected
Fatalities, should be fixed to restrict entry of
proper scaffolds
Scaffolding serious unauthorized workers
materials. Not
4. erection and injuries, 3 5 15 High 6. Scaffold accesses to be kept clear of 2 2 4 Low
obtained working
dismantling minor obstructions
at height permit
injuries, 7. Barriers to be used where appropriate
and no task brief
property 8. All persons erecting/dismantling scaffolds are
been conducted. to wear appropriate PPE. Fall prevention
damage
Not using proper systems are to be used and all running lines
PPE. No life line. and anchors are to be inspected.
9. Work to be stopped during adverse weather
conditions.
10. Loading of scaffold must comply with design
criteria and applies to both men and materials.
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Owner: HKN Network
N P I V R P I V R
11. Incomplete scaffold must be clearly identified
with red scafftag and where feasible, a barrier
across access.
12. Rescue plans are to be in place
13. TBTs are to be given
1. Relevant workers who handle this Chemical
should be trained to handle it safely
2. Containers of this product must be properly
 Skin labeled. Post signs, where appropriate in

storage and use areas.
damage,
3. Store containers of the product in a cool, dry
Handling  Irritation
location, away from direct sunlight and sources
Chemicals/  Improper use, and
of intense heat.
5. Storage spillages, respiratory 3 3 9 Medium 2 2 4 Low
4. Use correct PPE such as Respirators, Goggles,
(paints, splashes irritation
Gloves, etc.
sealant)  Ground
5. Usage system, storage and and first aid shall
contaminati
be accordance with MSDS and COSHH
on assessment.
6. In case of chemical spillage, immediately
cleaning shall be done.
7. In-case of inhalation or other body
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Owner: HKN Network
N P I V R P I V R
contamination, HKN medical team shall be
contacted
8. Waste material should be kept/ stored and
disposed with the compliance of respective
MSDS or CoSHH
9. Weather and wind director to be takn into
consideration and adeqwuate measures to be
implemented
 Breaking of wheel 1. Toolbox talk should be done prior to starting
 Changing of wheel work
 Motion of grinding  Serious 2. All connections to be checked prior to starting
injury the work and manufacturer’s specified

disc
instruction should be complied with.
Grinding/  Short circuits  Electric
3. Ensure all workers are trained, experienced
Bristle  Improper use shock
6. 4 4 16 High and competent to do the job 2 2 4 Low
blasting  Wrong connection  Cuts
4. Unplug the power tool after work shift or as
work  Dust particles  Fire
necessary after completion of the activity.
 Using  Laceration
5. Periodic inspection of the electrical
grinders/bristle Hearing connection.
blaster without  Impairment 6. Proper fire control should be installed near
guards, the hazardous materials. The hazardous
64
Owner: HKN Network
N P I V R P I V R
 Excessive noise material storage should be ventilated.
generation, 7. Machine to be properly held with both hands
 Workers not during the operation.
wearing PPE, 8. Machine should be applied with normal force

(Do not apply excessive force/pressure) to
 Working at height
avoid breakage of the grinding disc.
unsafely,
9. Hot work permit conditions to be applied.
 Inhalation of
10. Specified PPE must be worn during the
dust/fumes
specified operation.
11. Use the correct grinding disc
12. The speed of the machine must not exceed
the maximum permissible speed of the wheel
13. Grinder must be fitted with safe guard and
handle.
14. Power tool must be inspected and color
coded.
15. Prepare Working platform shall be provided
during working at height.
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Owner: HKN Network
N P I V R P I V R
1. Proper Instruction must be given prior to start
 Personnel falling the work (TBT)
from heights due to 2. Prepare safe Access/ Ladder/ Working
non-compliance to platform shall be provided.
wearing of proper 3. All operatives shall use full body harnesses
PPE/ unsafe and anchor to suitable place over head.
platform 4. Working platform shall be tested and certified
 Inappropriate use by competent Inspector and green tag
 Fatalities,
Work at of access provided
7. serious 4 4 16 High 2 2 4 Low
Height equipment 5. Provide life line where necessary
injuries
 over reaching, 6. Closely monitor the activity by Supervisor.
stretching etc, 7. Provide / issue proper PPE to all personnel
uneven floor working at high elevation and wear it properly
 persons colliding 8. Access ladders shall be fixed properly.
with obstacles 9. No materials stacking on the platform and no
 Manual handling- tripping hazards.
 Unstable loads 10. Full time supervision required
Working at height Fatalities, 1. Relevant, authorized workers and supervisors

Installation
8. Open edges serious 4 5 20 High involved in the operation should be trained in 2 2 4 Low
and testing
Limited access injuries, the particular method statement to be used.
66
Owner: HKN Network
N P I V R P I V R
Repetitive motion strains, cuts, 2. Follow safe installation practices using
Risk of being hit by pinches, slips, appropriate lifting gear in accordance with the
swinging pipes during trips and minor lifting plan and in the presence of lifting
lifting, Fusion Welding injuries supervision
Bursting of including 3. PPE is to be worn at all times.
pipes/releasing of burns 4. Wear gloves when tying pipes on to rebar
pressure from loose/ 5. Only trained operators to use fusion welding
damaged machine and gloves are to be worn at all
components times.
Electric shock 6. Hand tools are to be fixed to lanyards and
securely fitted to avoid falling.
Without oxygen test 1. All the workers should be followed the confine
and proper space work permit , Signal man/banks man
Inhalation of
Arrangement person must be present
noxious gases
entering to confined 2. Gas test shall be done and provide the
Confined problems
space 4 5 20 High ventilation 2 2 4 Low
9. space breathing
3. Do not bring fuel or fuel containers into the
poison gas.
No watchman and confined space and no ignition inside.
Unconsciousn
communication 4. Appointed a supervisor (with work experiences
ess or death
system not applied in confined spaces works)
5. Proper verbal communication system shall be
67
Owner: HKN Network
N P I V R P I V R
Proper access not used
provided and no 6. Any liquids or free-flowing solids are removed
supervisor for from the confined space to eliminate the risk of
monitoring drowning or suffocation
7. Watch man shall be appointed and full time
Inadequacy of supervision required.
access/egress 8. After completion of work, permit shall be
closed.
Inadequacy of work 9. Only physically fit and experienced workers to
space & restrictions in be used.
body movements 10. Stand by with (emergency recovery) measures
and record all activities in a time sequence.
Inadequacy of 11. Rotate/change workers periodically if required
illumination,
ventilation
High temperature
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Owner: HKN Network
N P I V R P I V R
12.2 SPECIFIC RISK ASSESMENT
1. Provide pre-works TBT and works activities

and provide constant works supervision.
2. Obtain a work permit and act accordance
Excavation collapse / 3. Keep Excavation and other machinery at least
Machinery Workers and 1m away from the excavation edge.
movements / machinery 4. Barricade the area and provide signage
Dewatering pump falling into 5. No materials or equipment keeping near the
failure, No work the excavation edges.
permit obtained, excavation 6. Provide suitable access/ Egress
10. Excavation 4 4 16 High 2 2 4 Low
Excavated area has causing 7. Provide adequate lighting and assign a
been kept open property watchman.
without warning damage 8. No one is to enter the excavation until the
signs, not providing of and injury shoring is completed / inspected and passed
proper access/ Flooding safe for use
egress 9. Dewatering pump to be inspected and colour
coded fit for use. In case of pump failure a
second stand-by pump to be immediately
available.
69
Owner: HKN Network
<Risk Assessment Matrix>
LEGEND
P Probability
I Impact
V Risk Value
R Risk Classification
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Method Statement for HDPE Pipe
Date & Version: 08-02-2019 Rev. D Extension from Retaining Wall to
External Manhole for Waste and Rain HKN-MST-ME-0321
Author: HKN
Water Pipe Network
5.3 Confined Space Permit
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Author: HKN
Water Pipe Network
75
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Author: HKN
Water Pipe Network
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Author: HKN
Water Pipe Network
77
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Author: HKN
Water Pipe Network
5.4 Hot work Permit
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Author: HKN
Water Pipe Network
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Author: HKN
Water Pipe Network
5.5 Pressure Testing Work Permit
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Author: HKN
Water Pipe Network
5.6 CoSHH
CoSHH of ZRC Cold Galvanizing Compound HKN-COSHH-ME-0015 - Status A
CoSHH of Sealant acetate white 310ML HKN-COSHH-ME-0002 - Status A
CoSHH of Water Stop RX-101 HKN-COSHH-CN-0040 - Status A
CoSHH of Mapefil GP HKN-COSHH-CN-0004 - Status A
CoSHH of Portland cement HKN-COSHH-CN-0001 - Status A
SECTION 6: TESTING & INSPECTION PLAN

6.1 Terms and Definition
Employer (EMP) : Waterfront Properties (Private) Limited.
Engineer (ENG) : Balmond Studio.
Contractor (HKN) : HYUNDAI-KEANGNAM-NAWALOKA Joint Venture.
Subcontractor (SUB) : Frigi Engineering Services (Pvt) Ltd - Building 1 & 3
Dae Jung E&C (Pvt) Ltd - Building 2
Mukyung E & C Co., Ltd - Building 4, 5 & 6
Hold Point (H)

A designated point during or following a specific activity Work may not proceed beyond this point until the
inspection has taken place and been witnessed by the required parties.
Witness Point (W)
A designated point during of following an important activity at which inspection or examination is required in
accordance with the relative procedure. Work may proceed through the designated witness point if the inspector is
not present for the previously established activity.
Spot Witness Point (SW)
A designated point during or following an activity at which spot inspection or spot examination is required in
accordance with the relative procedure. Work may proceed through the designated witness point if the inspector is
not present for the previously established activity.
Review Point (R)
It is processed through reviewing any results of inspection or test as a method of ensuring that the inspection or
test is performed in accordance with any approved drawing, procedure, specifications or acceptance criteria.
Surveillance (S)
It is processed through the routine act of monitoring or observing to verify an item or activity conforms to specified
requirements.
- N/A: Not applicable.
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Author: HKN
Water Pipe Network
6.2 Inspection Level

For the field inspection items agreed to be classified as Category A, B, C HKN JV may proceed with the
inspection or test.
For Category D, E field inspection items, inspection procedure is as follows;
1. HKN JV shall give the “Inspection/Test Request” to the Engineer, a minimum of one working day prior to
the proposed inspection.
2. If it becomes necessary for the Contractor to change the schedule (date and or time), he shall accordingly
notify the Engineer of the proposed change.
3. Category D, E inspection shall be scheduled by the HKN JV only during working hours as defined in
Contract Agreement. In case that the night shift working crew are organized, the witness inspection will be
scheduled in night time.
4. For the items fabricated by subcontractor from outside of Sri Lanka, QC Engineer shall provide quality
verification documents to Engineer for required Witness / Hold points.
Generally, Inspection Checklist will be signed by the inspector who is involved the inspection activity only. (In case
Category A, B and C items signature column for Company shall be made “N/A”.
Classification of Field Inspection is described as below,
Type Symbol
Contractor’s Surveillance CS
Contractor’s Review CR
Contractor’s Witness CW
Contractor’s Hold Point CH
Engineer’s Witness EW
Engineer’s Hold Point EH
Category Combination of Types

A CS
B CR
C CW
D EW & CH
E EH & CH
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Author: HKN
Water Pipe Network
6.3 Inspection List and Level

Participation by
Report Inspection HKN
No. Description of Inspection / Test Remarks
Form Level SUB QA/ ENG
ME
QC
1 MIR Check List E H H H H
2 Setting Out and Excavation Check List C H H W S
Fabrication of GEBERIT HDPE

3 Check List C H H W S
pipes
Fabrication of AGRU HDPE
4 Check List C H H W S
pressure pipes
Installation of GEBERIT HDPE
5 Check List D H H H S
pipes
Installation of AGRU HDPE
6 Check List D H H H S
pressure pipes
Installation check and Leak testing
7 for GEBERIT HDPE pipes (Before Check List E H H H H
backfilling)
Installation check and Pressure
8. testing for AGRU HDPE pressure Check List E H H H H
pipes (Before backfilling)
9. Back filling trenches Check List E H H H H
Legend : R-Review S-Surveillance W-Witness H-Hold N/A-Not Applicable
83
Page: 84/92
Author: HKN
Water Pipe Network
6.4 Check Lists

Annexure 1
Note: This document should be attached with ‘Back filling trenches’ inspection request is raised
84
Page: 85/92
Author: HKN
Water Pipe Network
Annexure 2
Waterfront Integrated Resort
HYUNDAI-KEANGNAM-NAWALOKA JV
INSPECTION CHECK LIST – Setting Out and Excavation
REPORT NO.: DATE:
DISCIPLINE: MECHANICAL SUBCON:
LOCATION DESCRIPTION: Project wide

REF.DOC.NO:
ACCEPTED BY
REMARKS
NO. DESCRIPTION OF INSPECTION / TEST
SUB HKN ENG
ME QA/QC
Setting Out
1 Approval received for shop drawing
2 Grid line / off lines provided
3 Dimension from grid/ off line
4 Invert levels as per the approved shop drawing

Expected breaking depth and width marked on the
5
ground
Excavation
Maintained trench width and depth as per approved
6
shop drawing
Safety precautions such as barricade sides of trench
7
to be excavated
8 Safety, Access, Egress, Lighting etc.
COMMENTS:
HKN
ENG. ENG / CONSULTANT
ME QA/QC
Date :
Time :
Name :
Signature :
Note: This document should be attached with ‘Back filling trenches’ inspection request is raised.
85
Page: 86/92
Author: HKN
Water Pipe Network
Annexure 3
INSPECTION CHECK LIST - Fabrication OF GEBERIT HDPE pipe
REPORT NO.: DATE:

REF.DOC.NO:
ACCEPTED BY
NO. DESCRIPTION OF INSPECTION / TEST REMARKS
SUB HKN ENG
Fabrication OF GEBERIT HDPE pipe ME QA/QC
1 Correct tools and equipment
2 HDPE trained plumber
3 Availability of approved Shop Drawing
4 Piping material
5 Diameter of pipe
6 Correct fittings
7 Correct dimensions
8 Alignment of the pipeline
9 Welding joint
10 Quality of workmanship
COMMENTS:
HKN
ME QA/QC
Date :
Time :
Name :
Signature :
86
Page: 87/92
Author: HKN
Water Pipe Network
Annexure 4
INSPECTION CHECK LIST - Fabrication OF AGRU HDPE pressure pipe
REPORT NO.: DATE:

REF.DOC.NO:
ACCEPTED BY
NO. DESCRIPTION OF INSPECTION / TEST REMARKS
SUB HKN ENG
Fabrication OF AGRU HDPE pressure pipe ME QA/QC
1 Correct tools and equipment
2 HDPE trained plumber
3 Availability of approved Shop Drawing
4 Piping material
5 Diameter of pipe
6 Correct fittings
7 Correct dimensions
8 Alignment of the pipeline
9 Welding joint
10 Quality of workmanship
COMMENTS:
HKN
ME QA/QC
Date :
Time :
Name :
Signature :
87
Page: 88/92
Author: HKN
Water Pipe Network
Annexure 5
INSPECTION CHECK LIST – Installation of GEBERIT HDPE pipes
REPORT NO.: DATE:

REF.DOC.NO.
ACCEPTED BY
No. DESCRIPTION OF INSPECTION / TEST HKN REMARKS
QA/
SUB ME QC ENG
Installation of GEBERIT HDPE pipes
1 Bed laying
2 Availability of “For Construction” Drawing
3 Pipe material
4 Diameter of pipe
5 Pipe path
6 Correct level/slope
7 Temporary protection
COMMENTS:
HKN
ME QA/QC
Date :
Time :
Name :
Signature :
88
Page: 89/92
Author: HKN
Water Pipe Network
Annexure 6
HYUNDAI-KEANGNAM-NAWALOKA JV9
INSPECTION CHECK LIST – Installation of AGRU HDPE pressure pipes
REPORT NO.: DATE:

REF.DOC.NO.
ACCEPTED BY
QA/
SUB ME QC ENG
Installation of AGRU HDPE pressure pipes
1 Bed laying
2 Availability of “For Construction” Drawing
3 Pipe material
4 Diameter of pipe
5 Pipe path
6 Correct level/slope
7 Temporary protection
COMMENTS:
HKN
ME QA/QC
Date :
Time :
Name :
Signature :
89
Page: 90/92
Author: HKN
Water Pipe Network
Annexure 7
INSPECTION CHECK LIST – Installation check and Leak testing for GEBERIT HDPE pipes (Before backfilling)
REPORT NO.:
DATE:
DISCIPLINE: MECHANICAL
SUBCON:
REF.DOC.NO:
ACCEPTED BY
QA/
SUB ME QC ENG
Installation check and Leak testing
1 Pipe path
2 Pipe joints
3 Pipe and seal
4 Medium - Water
5 Pre – defined Level
6 Test Duration - 4 Hours

Level Drop –No level drop other than the tolerance of
7
20mm
COMMENTS
HKN
ME QA/QC
Date :
Time :
Name :
Signature :
90
Page: 91/92
Author: HKN
Water Pipe Network
Annexure 8
INSPECTION CHECK LIST – Installation check and Pressure testing for AGRU HDPE pressure pipes (Before
backfilling)
REPORT NO.:
DATE:
DISCIPLINE: MECHANICAL
SUBCON:
REF.DOC.NO:
ACCEPTED BY
HKN REMARK
No. DESCRIPTION OF INSPECTION / TEST
QA/ S
SUB ME QC ENG
1 Pipe Joints
2 Fitting Connection
3 Medium – Water
4 Operation Pressure (Pump head)
Test Pressure - (one and a half times operating
5
pressure)
6 Test Duration - 2 Hours
7 Pressure Drop - not more than 0.2 bar
8 Calibration certificate for the pressure gauge
COMMENTS
HKN
ME QA/QC
Date :
Time :
Name :
Signature :
91
Page: 92/92
Author: HKN
Water Pipe Network
Annexure 9
HYUNDAI-Keangnam-NAWALOKA JV
INSPECTION CHECK LIST – Backfilling Trenches

REPORT NO.: DATE:
REF.DOC.NO:
ACCEPTED BY
QA/
SUB ME QC ENG
Backfilling Trenches
1 Leak testing completed
2 Back fill material
2.1 Material is suitable
3 Compaction
3.1 Back fill trench in 300mm layers
3.2 Compacting backfill layers
Laying warning marker tape in 300 to 400mm below
3.3
the level of the finished surface
4 Photo evidence
4.1 Photos during soil compacting
4.2 Photos after pipe laying
4.3 Photos during granular filling
4.4 Photos of warning & identification tape with tracer wire
5. Safety, Access, Egress, Lighting etc.
COMMENTS:
HKN
ME QA/QC
Date :
Time :
Name :
Signature :
92

HKN MST Me 0321 Rev. D DRR

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Document Review Report

Project Waterfront Integrated Resort, Colombo Seq. No. 5440

Method statement for HDPE Pipe

From: Reviewed by:

Acknowledged Receipt Date:

Please see attached:

BALMOND/STUDIO DOCUMENT REVIEW REPORT

From : Reviewed by:

Project: Waterfront Integrated Resort

Dae Jung E & C (Pvt) Ltd

[WR21] Method Statement for HDPE Pipe

COMMENT RESPONSE SHEET

Testing pressure should not be lower than

SECTION 1: GENERAL INFORMATION

Project: Waterfront Integrated Resort

Mr. D. M Thilakarathne (MK) Tel: 0713850115 HKN Safety Officer

Access Lighting (safety lighting):

Hazardous Materials and Substances:

Special Control Measures:

Working at Height Considerations:

 All the materials should be approved.

 Plan construction activity according to approved

 Arrange resources as per the schedule.

 Execute the construction schedule/plan provided by

 Representative of Safety dept.

 Make sure to arrange the safety induction program for

 Install and maintain wiring, control, and lighting

 Carryout fabricator work as per approved shop

 Receiving and issuing the material.

 The HKN Senior Scaffolding Supervisor will report

 All scaffolding inspectors (Sub-con) shall report to

 Senior scaffolder with more than 3 years active

 Follow site supervisor’s instruction to carryout daily

SECTION 2: DESCRIPTION OF WORK

2.2. Scope of Work

Sketch 3.3.a – HDPE pipe extension to external manhole

Sketch 3.3.b – Section A – A

2.4. List of Materials

Material MSB Ref. Status Uses

2.5. Material Storage

 Stored material shall be closely monitored on a regular basis.

2.6. Key Plan of Installation

Sketch 2.6 - Key plan of installation

2.7. Work Quality Flow Chart

Leveling Concrete Pass Fail

First stage Backfilling Warning and identification tape

Approved Not approved

By Civil Department (Details are

Documents to be approved prior to proceed work. (MSB, MST, CoSHH, SPD)

2.8. Method Statement Submission Plan

No MST No. MST Name Description Scop Approval Rev. No.

Grease Water (Kitchen) Up to 1st GS - piping

Method Statement for Installation of ACO

Installation of External Perforated Pipe for Under Ground RW Perforated pipe

Installation of Internal component and Oill Separator

Sewer, Waste Water (Ex. M.H to City Main) - Piping System

Conventional R.W system - Pumping Pit & Accessories

HDPE pipes (Corrugated)

Conventional R.W system - Final Testing & Com. 3.1.2.2.1.4

Oil separator - Final Testing & Commissioning 3.1.3.3

Marking and Identification for Waste and

HDPE pipe extension from retaining wall

3.1.1.1.1 Conventional System [HKN-MST-ME-0019 / 20 / 23] [ WR 1/2/3]