Annex 06

WORKING PROCEDURES AND INSTRUCTIONS

ACTIVITY: SITE CLEARANCE
1. PROCEDURE
Before construction, the site should be in a cleared and graded condition. Jiangsu will remove the trees,
demolishing buildings, any and all old underground infrastructure, and any other obstacles that might affect the
construction process in the future or hinder the project to be done.

2. OCCUPATIONAL RISKS
 Falls to the same level
 Cuts and other injuries
 Running over
 Particle Projection

3. PREVENTION MEASURES
- Whenever there is interference with the clearing works and pedestrian crossing, machinery shall be
organized and controlled by auxiliary trained personnel duly to monitor and direct their movements.
- Machinery operators shall check headlights, indicator lights and stop lights, and inspect the condition of the
tyres.
- People are not allowed close to the equipment.

4. PERSONAL PROTECTION EQUIPMENT

- Protective Helmet
- Respirator
- Signaling Vest
- Protective Gloves
- Protective Boots

ACTIVITY: EXCAVATION
1. PROCEDURE
Prior to trench excavation, the layout drawing should be carefully read, and surveying lead line of pipe shall be
marked at site. After approval of supervising engineer, underground existing utilities along pipeline should be
investigated and detected by means of inquiring from related local authority, even so test pits should be
excavated at the interval of around 20 meters so as not to damage the existing underground utilities.
Trench shall be excavated as per the designed elevation and lead line. During excavation, due to use of
machine, the trench bottom should be left for manual excavation at least 10-15cm if no groundwater, then
manpower shall be arranged for the final clearance and levelling of bottom. If the part of trench bottom is over-
excavated, the sand or soil free of stones shall be used as backfilling material and simply compacted as it is
necessary.
If the material of trench wall is loose and easy to fall down, the efficient and suitable measures of wall support
shall be taken to ensure the safety. During the excavation the distance between pipeline and wall or fence of
the existing house should be considered for safety reason. Normally the distance is not less than 0.8 meters.
The excavated materials shall be piled at one side of trench, and the other side will be used as access path for
transportation of pipe materials and construction area.

2. OCCUPATIONAL RISKS
 Fall in height or same level
  Burial
 Cuts and other injuries
 Electrocution
 Running over
 Dust
 Falling objects
 Detachment of land

3. PREVENTION MEASURES
- In trench excavation, Jiangsu will adopt the most appropriate containment solutions, taking into account the
following factors: ground cohesion, groundwater level and foreseeable accidents.
- Prior to commencing work, the ground will be checked for possible cracks or instability.
- All trenches more than 1.20 m deep must be naturally inclined or bent, and in any case the walls of the
excavation must be "cleared" of any loose elements;
- At all times when the trench is open, adequate access to the bottom of the excavation must be ensured,
either by stairs or other safe process that allows rapid escape in case of problems with the stability of the
excavation.
- In the case of accesses dug into the slope, they will be reinforced with the laying of a balcony and wooden
steps.
- The excavation materials must not be placed near the edge of the trench and it is necessary to ensure an
appropriate clearance (to be established case by case, but never less than 1/3 of the depth) in order to
prevent the excavation material from falling - if the excavation is bent and the bent is raised, excavation
materials may be deposited against this parapet, so the natural slope of this deposit does not exceed this
parapet in height;
- The equipment should always circulate away from the trench boundaries, with a minimum of 0.60 meters,
in such a way to prevent vehicles from falling. Such boundaries may consist of orange polyethylene nets at
least 1.00 meters high (if there is no risk of vehicles falling).
- At the boundaries of the trenches accessible for persons, the guardrails must be mounted at a suitable
distance to ensure adequate collective protection against the risk of falling.
- The guardrails will be used as collective protection in ditches higher than 1.50 m.
- The placement of any work support equipment (compressors, generators, etc.) or material close to the
trench edges shall be prohibited and adequate clearance not less than 60 cm must be kept;
- Every day, before starting any work inside the trenches, the stability of those trenches will be checked
(existence of cracks in the ground, defects in shoring material, etc.);
- The lifting and hauling equipment should be stabilized and be away from the trench edge.
- The approaching of vehicles to the edge of the trench for material transportation will be made within a safe
distance.
- Any materials will be placed more than 0.60 meters from the edge of the trench thus preventing accidental
overloads.
- Persons are not allowed to access to the dangerous area of the turntable.

4. PERSONAL PROTECTION EQUIPMENT

- Protective Helmet
- Protective Gloves
- Protective Boots
- Signaling Vest
- Respirator
- Goggles

ACTIVITY: PIPE LAYING AND CONNECTION

1. PROCEDURE
All the welding personnel shall be experienced or well trained, ensuring that they are qualified to perform the
welding works. The number of welding machines and personnel shall be adjusted according to actual quantity
of work and construction progress.
Two kinds of butt fusion welding machine will be used for connection of HDPE pipes. One is manual push type,
which normally will be used for connection of HDPE pipes with diameter smaller than 200mm.Another is
hydraulic push type, which normally will be used for connection of HDPE pipes with diameter bigger than
200mm.
Place the whole equipment on a stable and dry ground, make sure the machine is in good conditions before
welding. Check if there are scratches or fissures on the surface of pipes or fittings. If the depth of scratches or
fissures exceeds 10% of the wall thickness, cut the section of pipe with the scratches or fissures.
Place the pipes/fittings in inserts of frame and keep the ends to be welded be the same length (no effect on the
planning and heating of the pipe). The pipe out of basic frame should be supported to the same central axial of
clamps. Fasten the screws of clamps to fix the pipes/fittings.
Open fully the pressure regulation valve, lock the swing check valve tightly and then push forward the direction
valve meanwhile adjust the regulation valve till the cylinder begin to move, at this point the pressure in the
system is the drag pressure.
Open the pipes or fittings ends after turning swing check valve anti-clockwise to the end. Put the planning tool
between the pipes or fittings ends and switch it on. Close the pipes or fittings ends by acting on the direction
valve meanwhile slowly turn swing check valve clockwise until homogenous shavings appear from both sides.
Turn the swing valve anti-clockwise to relief the pressure, in a moment later open the frame, switch off the
planning tool and remove it.
Close the pipes or fitting ends and check the alignment of them. The maximal misalignment should not exceed
10% of the wall thickness, and it could be improved by loosening or tightening the screws of clamps. The gap
between two pipe ends should not exceed 10% of wall thickness; otherwise the pipes or fittings should be
planed again.
Clear the dust and slit on heating plate (Don’t scratch PTFE layer on the surface of heating plate) and make
sure the temperature has reached the required one.
Put the heating plate between the pipes ends. Close the pipes/fittings ends by operating direction valve and
raise the pressure up to specified pressure by swinging pressure regulation valve till the bead reaches required
height.
Open the frame and take out the heating plate and close two melting ends as quick as possible. Keep the bar
of direction valve on the close position for 2-3 minutes, put the bar of direction valve on middle position and
press the time button to count cooling time until it is over. Finally open clamps and take out the jointed pipe.
Before laying the connected pipe, make sure that pipe bedding has already been put 10 cm thickness of sand.
After that, laying the pipes into trench.

2. OCCUPATIONAL RISKS
 Fall in height or same level
 Cuts and other injuries
 Burial
 Electrocution
 Falling objects

3. PREVENTION MEASURES
- Provide secure stockpile area for pipes and fittings.
- Minimize height of pallets / stockpile.
- Maintain control of loads when lifting & moving.
- Apply appropriate signage and pedestrian control.
- Ensure security and equipment suitable to minimize vandalism.
- Keep area clean & clear of obstacles.
- Conduct site inspection to ensure access/egress is adequate for the task activities
- Maintain a safety working area around moving equipment.
- Maintain (specified) appropriate spillage control equipment.
- No load to be placed or moved near the edge of excavation where it is likely to cause collapse of side of
work.

4. PERSONAL PROTECTION EQUIPMENT

- Protective Helmet
- Protective Gloves
- Protective Boots
- Signaling vest
- Respirator

ACTIVITY: BACKFILLING AND COMPACTION

1. PROCEDURE
Backfilling will be executed in layers and the thickness of the layers shall be maximum 30 cm in height.
Soil will be spread in layers in accordance to the layer thickness. Each layer will be compacted either by plate
or roller compactor depending on the size of the area to be filled.
Compacting the spread layer as required and making in site compaction test.

2. OCCUPATIONAL RISKS
 Fall in height or same level
 Burial
 Cuts and other injuries
 Running over
 Dust
 Falling objects
 Detachment of land

3. PREVENTION MEASURES
- Every day, before starting any work inside the trenches, the stability of those trenches will be checked
(existence of cracks in the ground, defects in shoring material, etc.);
- Every day, before starting any work inside the trenches, the condition of related equipment will be checked
carefully.
- Persons are not allowed to access to the dangerous area of the turntable.
- Whenever there is interference with the backfilling works and pedestrian crossing, machinery shall be
organized and controlled by auxiliary trained personnel duly to monitor and direct their movements.
- The equipment should always circulate away from the trench boundaries, with a minimum of 0.60 meters,
in such a way to prevent vehicles from falling.
- People are not allowed close to the equipment.

4. PERSONAL PROTECTION EQUIPMENT

- Protective Helmet
- Protective Gloves
- Protective Boots
- Signaling Vest
- Respirator
- Goggles

ACTIVITY: PRESSURE TESTS

1. PROCEDURE
Water used for testing should be fresh water. The testing mechanical pump shall be used for increasing the
pressure up to test pressure. In general terms, the length of sections to be tested should not exceed 1000
meters, except in special conditions duly approved by the engineer. Normally the test pressure should be 1.5
times of service pressure. The test procedure briefly includes installation of test device and filling of water into
test pipes.
During filling water, air inside the pipe should be exhausted. After finishing of filling water, this test section shall
be maintained with pressure for 24 hours, during this period, visual inspection shall be carried out in order to
detect leakage.
Increasing the pressure gradually till reaching the test pressure. During this period, regular inspection should
be done.
After reach the test pressure, the value should maintain 3 hours without change or the change is complying
with the requirements of technical specification.

2. OCCUPATIONAL RISKS
 Electrocution
 Cuts and other injuries
 Punctures and Crushes
 Collapse of neighboring structures
 Multiple burst injuries

3. PREVENTION MEASURES
- Ensure pipe not damaged.
- Ensure adequate support where a change in direction or reducer occurs.
- Don’t exceed pipe operating pressure, ensure pipe is correct diameter.
- Provision for a pressure gauge, stop valve and bleed valve is compulsory.
- Appropriate training and instruction in procedures for workers involved in the test.
- Designated test/exclusion zone.
- Lock-out/tag system to prevent persons other than those involved in the test from accidentally releasing
pressure.
- Consideration of the effects of hydro-static head pressure on the system in test.
- Adequate signage/information for persons other than those involved in the test.
- Protection of pipe-work and fittings with the potential to be damaged.
- To prevent joint or pipe section failure, fix brackets close enough together to prevent excessive movement.

4. PERSONAL PROTECTION EQUIPMENT

- Protective Helmet
- Protective Gloves
- Protective Boots
- Signaling Vest

ACTIVITY: FORMWORK
1. PROCEDURE
All formwork activities will be carried out in accordance with the specification.
Ensure that the props, shores, waling, bearers, clamps and tie rods are the right size and at the correct
spacing. The Formwork designer shall check the falsework system with respect to load imposed on it and
design parameters as laid down in the specification.
Forms fastened to previously cast concrete must be tightly fixed to prevent grout loss. Cellular foam plastic
strips can be used to make a seal.
Check quality of shutter lining, tightness of bolts and wedges, built-in items, inserts and other embedments.
Particular attention will be paid to the rigidity and line of stop ends and joint formers. Remove all tie-wire
clippings and nails, which may stain both the formwork and the concrete.
Ensure that adequate access and working platforms are in place for the concreting gang and that toe boards
and guardrails are provided. A spreader or lifting beam shall be used to prevent distortion when placing
formwork. Adjustable steel props shall be erected in plumb and verticality of props checked using a spirit level.
A prop should not be used if it is bent, creased or, rusted or has a bent head or base plate, damaged pin etc.
Proper release of agent shall be used so that it can be removed without damaging the surface finish of the
concrete. New timber and plywood forms shall be given first coat of the appropriate release agent 36 hours in
advance, then a second coat just before they are used. Avoid excessive use of release agent as this can
cause staining or retardation of the concrete.
A close watch should be kept on all wedges and fastenings. Make sure that they do not work loose. Grout loss
is an indication that some movement has occurred.

2. OCCUPATIONAL RISKS
 Fall in height or same level
 Falling objects
 Crushing
 Cuts and other injuries
 Punctures
 Collision
 Electrocution
 Burial by collapse of parts of the formwork

3. PREVENTION MEASURES
- The presence of personnel in the work areas during the hoisting, joisting, propping rebar operations is
strictly prohibited.
- The use of regulatory stairways to climb up to the casing panels is mandatory.
- Working from fully completed permanent or temporary work platforms e.g. not climbing on handrails or
guardrails to gain extra height
- Checking all required supports, bracing and ties are installed as the erection progresses
- Checking live loads arising from the erection work for the stage of completion—the number of workers and
plant items on the structure at any one time may need to be limited
- Tying props and frames laterally to prevent movement
- Providing adequate bracing between falsework frames to keep the structure rigid, and having all props and
frames bearing fully and evenly on their foundations.
- The nails in the wood used shall be removed as soon as possible.
- The nails shall be stacked up for a proper removal.
- Every electric machine shall have ground and differential switch protection.
- The stability of the casing panels and reinforcement shall be checked prior to pouring the concrete.
- After the completion of work, the work area shall be cleaned and all materials shall be stacked up for the
following removal.

4. PERSONAL PROTECTION EQUIPMENT

- Protective Helmet
- Protective Gloves
- Protective Boots
- Signaling Vest
- Goggles
- Safety Harness

ACTIVITY: CONCRETE
1. PROCEDURE
Concrete will be mixed on the site for placing and compaction. The Contractor shall inform the Engineer before
concrete starts and shall give the Engineer sufficient time to inspect the work which is to be concreted.
Concrete workers for compaction shall be properly trained in the use of vibrators prior to commencing work.
Concrete which in the opinion of the Engineer is no longer sufficiently workable shall not be placed in the
permanent work. Concrete shall be placed as close as practicable to its final position and shall not be moved
into place by vibration. Contractor shall make sure that concrete shall not to fall freely more than 2.7 m during
concreting work even by using of chute.
Unless otherwise permitted by the Engineer, concrete shall be compacted by means of internal vibrators of
suitable diameter. A sufficient number of vibrators shall be maintained in serviceable condition on the Site to
ensure that spare equipment is available in the event of breakdown.
Vibration shall not be applied by way of the reinforcement, and contact between internal vibrators and
formwork, reinforcement or built-in components shall be avoided as far as possible. Concrete shall be vibrated
in such a manner that the formwork, reinforcement or built-in components will not be displaced.
Internal vibrators shall be pushed down into the freshly placed concrete in an axial direction until the whole of
the concrete in their immediate vicinity has been vibrated to its full depth. They shall then be withdrawn slowly
and re-inserted in the next position. The vibrators shall be inserted deep enough to ensure that the top of the
previously compacted layer of concrete is also revibrated and the timing must be such that this layer is still
within the time limit for proper response to vibration.
After completion of the finishing process on the unformed faces of concrete, all surfaces exposed to air shall be
covered with a layer of approved material and all edges of which shall be security fixed such that no air
circulation can take place until such time as the concrete has hardened sufficiently to permit further protection.
The covering shall be removed and the concrete completely covered with hessian, sacking, or other similar
absorbent material, and the cover material shall be kept constantly wet.

2. OCCUPATIONAL RISKS
 Fall in height
 Falling objects
 Burial
 Bruises
  Electrocution
 Collapse
 Contact with concrete (dermatoses)

3. PREVENTION MEASURES
- Prior to pouring, the safe state of the casing formwork shall be inspected to prevent blowouts and spillages.
- The vehicles shall always be 2 meters (as a general rule) away from the ditches (or baffles) to pour the
concrete. There shall be buffing gear at that distance so as to ensure safety. (Dumper or cement mixer).
- Prior to pouring, the person in charge shall inspect the good condition of earth retaining shoring of
emptying slopes that are in the area of the wall that is going to be poured, to perform strengthening or
correction as necessary.
- Prior to pouring, and to cap off the casing formwork, upper part of the work platform shall be constructed
from where the work the pouring and vibrated concrete operations shall be carried out.
- The pouring of concrete within the casing panels shall be done by uniformly spreading same in regular
tonnes, avoiding punctual overloads that deform or burst the casing.
- Secure chock at the paths' end, for vehicles which travel to pour concrete near the edges of the trenches,
(Dumper, truck mixer) shall be installed.
- The correct layout and disposal and condition of the protections shall be inspection prior to pouring.
- The proper performance of the casing panels during the pouring shall be monitored, and the process shall
be stopped if any failure is detected.
- There shall be easy and secure accesses to get to the workplaces.
- The top slabs will be covered in order to prevent falls to a different level.
- Concentrating concrete loads in only a single point is strictly prohibited. Pouring shall be carried out by
spreading the concrete smoothly and over wide surfaces.

4. PERSONAL PROTECTION EQUIPMENT

- Protective Helmet
- Protective Gloves
- Protective Boots
- Signaling Vest
- Safety Harness

ACTIVITY: INSTALL THE VALVES (WATER METERS)

1. PROCEDURE
The valve should be inspected to make sure the opening is free from dirt and foreign matter. The flange faces
need to be free of dirt, grease, or any surface defects that may cause leakage. Also, the connecting pipeline
should be free of any foreign materials, such as rust or welding slag that could damage the seat and disc
sealing surface.
Actuators should be mounted on the valve prior to installation so the proper alignment can be made. Make
sure the valve, flanges, and pipe are all compatible with the correct pressure class and materials specified
before installation. Check the flange bolts or studs for the correct size and length. The connecting equipment
and lines should have the proper alignment prior to valve installation. When installing the valve and gaskets,
the pipe should be spread apart just enough to allow the valve and gaskets without actually coming in contact
with the flanges. Care should be taken to not damage the surfaces of the flanges or valve.

2. OCCUPATIONAL RISKS
 Fall in height
 Falling objects
  Burial
 Bruises
 Electrocution
 Collapse
 Contact with concrete (dermatoses)

3. PREVENTION MEASURES
- Valves must be inspected for dust, sand, iron oxide and other impurities before installation. If any of the
above debris must be cleaned up before installation.
- All valves must be equipped with gaskets of corresponding grade before installation.
- When installing flange doors, fasteners must be tightened, and flange bolts must be tightened in a
symmetrical direction in turn.
- In the process of valve installation, all valves must be installed correctly according to the system and
pressure. No random or mixed assembly is allowed. For this reason, all valves must be numbered and
recorded according to the system before installation.
- Avoid carelessly placing them outdoors or where there is a lot of dirt. In particular, be careful not to remove
the caps from the ends until the time immediately before installation.
- Before installing a valve on the piping line, check that the valve is the specified one by its marking, valve
name, valve number, etc., on the body surface.
- If foreign matter remains in the piping on which the valve is installed, the valve seat surface may be
damaged and a seat leak may occur. Therefore, thoroughly clean the piping and equipment.
- Check the flow direction arrow on the valve body before installing the piping.
- When installing valve piping, consider the operation space, maintenance space, and the installation of
chain blocks to lift heavy parts.
- Install the valve by a layout in consideration of daily walk round checks, lubrication, and maintenance.
- Install effective supports in piping to prevent excessive bending or twisting from acting on the valve due to
the valve outlet piping and the mass of highly charged fluid.
- Confirm that it is not loosen when water seal pipe is connected in valve.

4. PERSONAL PROTECTION EQUIPMENT

- Protective Helmet
- Protective Gloves
- Protective Boots
- Signaling Vest
- Safety Harness

ACTIVITY: PAVEMENT CUT AND REPAIR

1. PROCEDURE
The removal and replacement of portions of existing concrete pavement shall require breakout grooves to be
sawed by the use of an approved power driven concrete saw.
Locations shown on the plans are indicative only of the need for grooves, and where designated locations
coincide with or fall within three (3) feet of the present location of either construction joints, or expansion joints,
breakout shall be to existing joints; in this case, there will be no necessity for cutting additional grooves. Sawed
breakout grooves shall be cut perpendicular to the surface of the pavement and shall be sawed full-depth to
form a neat breakout line in the concrete pavement when the pavement is removed. The use of breakout
grooves sawed to a minimum depth of one and one-half (1.5) inches will be allowed in the alternative to full
depth only upon the approval of the Director of Public Works and Transportation.
Removal and replacement of sidewalks shall be to the nearest existing joint not damaged by the construction.
Street and alley pavement removals shall have no horizontal dimension less than three (3) feet and in concrete
pavements shall not leave any existing portion of pavement in place less than three (3) feet as measured to the
nearest joint or edge of pavement except that for curb and gutter, a gutter of at least 12 inches may remain,
provided that the curb and gutter is not damaged by the construction activity.
Pavement repairs are to be made as rapidly as is consistent with high quality workmanship and materials. Use
of fast setting concrete and similar techniques is encouraged insofar as possible without sacrifice of the quality
of the repair. Unless otherwise allowed by the supervisor, excavations on thoroughfares must be filled and
compacted or properly plated within 24 hours.

2. OCCUPATIONAL RISKS
 Electrocution
 Cuts and other injuries
 Running over
 Dust
 Contact with concrete (dermatoses)
 Bruises

3. PREVENTION MEASURES
- Prior to construction, the construction machinery should be inspected to ensure that the operation condition
of the machinery and equipment is safe and reliable.
- Prior to the construction, an obvious roadblock should be set in front of the road section, traffic signs
should be set up, and traffic guidance should be done.
- Operators of machinery and electrical equipment must be trained before they start the work.
- Keep the construction site clean and orderly. The construction machinery is neatly parked, and the
environment of the construction area is tidy.
- The construction machinery is prone to dust, we will do the dust reduction work, and sprinkle water in time.
- The construction personnel must work in the conical traffic sign enclosure area and set up a special person
for traffic control.

4. PERSONAL PROTECTION EQUIPMENT

- Protective Helmet
- Protective Gloves
- Protective Boots
- Signaling Vest
- Goggles