MS For Excavation and Backfilling of Underground Fire Water Pipe Line PGIS

Client / Owner: Contractor:
Power & Water Utility Company for Jubail

and Yanbu (MARAFIQ)
Project Title: Project No./Contract No.:

Fire Protection Upgrade, Jubail, Phase 1 PF13-144
Method Statement: Document No.:
PGIS-MOS-014
METHOD STATEMENT FOR EXCAVATION AND Revision No.: 00
BACKFILLING FOR UNDERGROUND FIRE WATER Date: 04/May/2015
PIPE (CIVIL WORK) Page: 1 of 19
METHOD STATEMENT FOR EXCAVATION,

BACKFILLING AND INSTALLATION OF
UNDERGROUND FIRE WATER PIPE (CIVIL
WORKS) – NWPS AREA
and Yanbu (MARAFIQ)

PGIS-MOS-014
SECTION NO. TITLE SECTION
1 SCOPE
2 MATERIALS
3 PERSONNEL DUTIES & RESPONSIBILITIES
4 TOOLS & EQUIPMENT
5 WORK PROCEDURE
6 INSPECTION
7 RISK ASSESSMENT
and Yanbu (MARAFIQ)

PGIS-MOS-014
1. SCOPE
This method statement is made to enumerate the activities involved in the
underground fire water pipe (Civil Works) to be performed as per the project
specifications and the procedures are compiled for uniformity and to assure all
level of staff is aware of the procedure to ensure the quality of the bonding
process.
The objective is to ensure that the installed piping system will meet the specified
performance requirements and also to ensure safety procedure involved in the
execution of the activity, according to the requirements of MARAFIQ in the
NWPS area Fire Protection Upgrade, Jubail Phase 1.
This method statement describes the steps to be followed to carry out TB/TS
adhesive bonded joints for GRE pipe
The procedure written in this Method Statement is as complete as possible; it is

not possible to describe all kinds of circumstances that may be encountered in
the field. For this reason our experienced site Engineer-Supervisor may vary the
described procedure in order to achieve an optimum solution using the latest
installation techniques and processing method.
2. MATERIALS
2.1. GRE Pipes, Fittings and Adhesive
3. PERSONNEL DUTIES AND RESPONSIBILITIES

3.1 Site Manager
Site Manager shall be responsible to provide his site teams with
appropriate resources to ensure that works are done in accordance with
the project safety and quality standards.
3.2 Construction Manager

He is the responsible for the multitude of tasks. He shall review the project
activities in depth and to manage the construction schedule in an effective
and efficient manner. He is the responsible person to lead the
construction crew as per project requirements.
3.3 Site Engineer

The Site Engineer will be the one to implement the instruction of the
Construction Manager in the site, he will also directly supervise constantly
the manpower and equipment working in the area and implement safety
all safety regulation and precaution set by the safety personnel.
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PGIS-MOS-014
 Program the work and explain the job to the concerned.

 Verify item that are dimensionally located on the drawing and
embedded item.
 Site Engineer shall organize and manage all activities related to
pipes and pipe supports installation including planning and
material arrangements, overall supervision to ensure that site
safety plan is in place and implemented.
 Overall supervision during installation of pipes and pipe supports.
 After confirming that all works were done according with this
Method Statement, he shall raise a Request for Inspection (RFI) to
the in-charge QC Inspector for all activities covered by the
Inspection and Test Plan (ITP).
3.4 Supervisor & Foreman

The Civil Supervisor shall be directly involved in the supervision, planning
and execution of all activities. He shall be responsible for the preparation
of work plan prior to commencement of work.
 Assigning the responsibilities to the skilled worker.
 Make sure that the pipe supports are installed properly in its
designations and the expansion bolt nuts should be tight.
 Make sure that the pipes are installed as per IFC drawing.
 Make sure that the expansion bolt nuts should be tight.
 Double nut shall be used on U-Bolts.
3.5 QA/QC Inspector

The QA/QC Inspector shall be responsible for the necessary inspections
and testing to be carried during the activities.
 Check the welding and bolting connection of pipe supports.
 Check the location and elevation of the pipe support.
 Check the pipe support alignment and bolt tightness.
 Check the pipe fit-up, welding and final connection of pipes.
 Check the piping straightness if it is within the allowable tolerance.
 Support when hydro testing is ongoing.
 Inspection must be carried out as per ITP/QCP
3.6 Safety Officer

Safety officer shall review each activity he shall ensure that safe working
plan and work permits are available in site. He must be implemented
safety procedure and observed during the concerned activity. Safety
officer must be basic first aid trained and Marafiq approved.
and Yanbu (MARAFIQ)

PGIS-MOS-014
4. TOOLS AND EQUIPMENT

All equipment and tools being mobilized on site will be certified and in good and
running condition. They shall be double checked and inspected by the
concerned personnel prior to use of them. The following are the equipment and
tools to be used.
Excavation
 Backhoe / Excavator
 Dump Truck
 Fuel Truck
 Water Truck
 Plate Compactor
 Concrete Cutter
 Dewatering Pump (if required)
 Spanner
 Shovel
 Rake
 Generator
 Scaffolding Materials
 Lighting System
 Warning sign and Signboards
GRE / GRP Pipes

 ATB/TS shaver
 Heating blanket 220 V (Diameters based on project specification)
 Temperature controller
 Pi Tape mm (Diameters based on project specification)
 Curve-o-mark
 Torque wrench with box spanner (Diameters based on project
specification)
 Spirit level
 Drilling machine
 Spirit level
 Latch belt
 Come-along-jack
 Drilling machine
 4" Angle grinder
 Pipe vise
 4" Cutting disc
 Emery disc
 Emery cup
and Yanbu (MARAFIQ)

PGIS-MOS-014
 Backing disc pad

 Rubber mandrel
5. WORK PROCEDURE
5.1 Site Preparation
5.1.1 Excavation for Underground pipe utilities shall be inspected from
its condition that could affect the excavation and cutting of
roadways and existing structure encounter during the
construction activities. Barricades and warning devices and shall
be posted prior to commence executing the works.
5.1.2 All necessary permits and risk assessment that required for the
excavation for underground pipe utilities must be provided and
available always at site during execution of work.
5.1.3 Access road should be taken to consideration for the entrance

and exit route and where to place the excavator during the
excavation for underground pipe utilities.
5.1.4 All tools and equipment shall be inspected prior to start the job.
5.2 Survey
5.2.1 Verify the detail of excavation according to the approved for
construction drawing before starting the excavations of works.
Conduct a survey and mark the location and the limits of the area
to be excavated. In marking the excavation s limits, consideration
should also be given for additional area to accommodate side
slopes of the excavation.
5.2.2 Determine the depth of the excavation from the existing ground
taking reference from the latest approved for construction
drawing.
5.2.3 All excavations shall be “flagged” off all the times. Barricade shall
be installed around the excavation area.
5.3 Excavation
and Yanbu (MARAFIQ)

PGIS-MOS-014
• All tools and equipment must be inspected and colour coded and if
found defective / damages should be removed immediately from the
site.
• Use right tools for job. Completed mark-outs of utilities
• Confirm location of all utilities and excavation area by hand digging
• Report immediately to the Marafiq for any unknown underground
installation encountered during excavation. Stop work and wait for
further instructions.
• Have competent person examine area before work.
• Excavations deeper than 3 ft. in depth require an excavation plan.
The required excavation plan must be complied with at all times.
• All excavation access and egress shall be inspected daily and
complete barricade and signs must be posted.
• Barricades and signage shall be posted in place.
• Set up barricade and signboards around the area to prevent unwanted
personnel entry to the excavation site.
• When heavy equipment such as backhoe and dump trucks are in use,
a trained flagman shall be assigned to direct the traffic at the place of
work and closely monitor the status of excavation work
• Excavate up to the desired level, width and length as required to
conform to the latest approved for construction drawing.
• When desired bottom elevation is reached, level and compact the
ground by using appropriate machine such as roller or plate
compactors up to the required density conforming to the project
specifications.
• During underground pipe excavation site condition allows, the sides
shall be sloped. Access for the excavator shall be provided. Heavy
equipment such as backhoe, dump trucks are in use, a trained
flagman shall be assigned to direct traffic at the place of work.
• Install barricades & warning signs at the work area in order to maintain
proper set back at 1 meter.
5.4 GRE / GRP Pipes Installation and Jointing

Inspection
It is important to inspect all the pipes and fittings or any components,
which are used in the system prior to assembling the joints. All pipes and
fittings shall be visually inspected for damages that may have occurred
during shipment. One hundred percent of the exterior surface shall be
inspected visually and the internal surface shall be inspected where
accessible. Damaged pipes/fittings should not be used in the system. If
and Yanbu (MARAFIQ)

PGIS-MOS-014
the damages are repairable, repair work shall be carried out in

accordance with the Wavistrong Repair Procedure and shall be used in
the system.
Adhesive bond kits shall be inspected prior to use, to ensure the specified
expiry date is valid to use the material. Storage condition for the adhesive
kits shall be strictly adhered to the specified storage instructions (Refer to
the brochure supplied with the adhesive kits) to achieve the optimum
performance of the product shall be carefully followed. The following two
sections apply only in the cases where a pipe has to be cut to suit site
conditions.
Socket Preparation
The bell end shall be abraded using an emery cup of grade 40 or 60
inserted in a rubber mandrel and fixed to a drilling machine as shown in
Photo
Precautions
The prepared bond surface area must not have any grease, oil, dust,
moisture, water etc. Soak a piece of cloth with acetone MEK (methyl ethyl
ketone) or MIBK and clean the surface. If the bond surface is cleaned with
solvents re-sanding shall be carried out to refresh the surface. Do not use
paint thinner, petrol etc. for cleaning purpose, dry brush can be used to
clean the spigot.
and Yanbu (MARAFIQ)

PGIS-MOS-014
Spigot & Bell Details
Spigot End (TS)- Figure 1
Bell End (TB) Figure 2
Fire Water
ID S1 (SA) BA α Min. Insertion Depth (mm)
mm mm mm mm degree
100 103.5 47.5 85 1.75 43
150 153.5 47.5 85 1.75 43
250 253.5 51.5 80 2.5 53
Table 1- Spigot & Bell details

and Yanbu (MARAFIQ)

PGIS-MOS-014
Cement Application
Prior to the application of cement on the spigot and bell, fix the latch belts
on both sides of the pipe. Leave enough working space between the
pipes to be jointed. Use wooden blocks to prevent damage from come-
along-jack. Ensure the pipe sections are adequately supported and
aligned properly. Check if the prepared bonding surface is clean and free
from dust, oil etc., sand it with an emery paper and make it fresh prior to
applying the adhesive mixture. The prepared bonding surface shall not be
touched with a bare hand or with dirty hand gloves. Clean the prepared
surface areas with a firm brush and ensure it is fully dry. Add the hardener
from the small container to the resin in the large container and mix with
the supplied spatula for about 3 minutes until the mixture has a uniform
color. Adhesive components shall not be mixed partially from the
container to avoid proportional mixing variations. However the expiry date
of the adhesive components shall be checked before using the product at
all times. Detail as shown in Photo-4.
Photo 4
Once the adhesive is mixed properly, apply a thin, uniform layer of

adhesive mixture to the freshly prepared bond surface of the bell end
(approximate. 0.5 mm thick). Do not apply excess quantity of adhesive
mixture to the bell end to avoid excessive formation inside the joint.
Detail, as shown in Photo 5.
and Yanbu (MARAFIQ)

PGIS-MOS-014
Photo 5
Apply the adhesive mixture to the freshly prepared spigot. The initial layer
shall be thin and uniform to ensure the surface area is properly wet with
the mixture. Once the entire spigot area is wet with the mixture apply a
second layer of adhesive to the spigot (approximate. 1.0 mm thick). It is
important to ensure that no dust, sand or any other particles are mixed
with the adhesive or on the mixture spread of the bonding surface. Detail,
as shown in Photo 6.
Photo 6
Assembly
1. In humid environment the prepared joint may need to be warmed up to
avoid moisture contents on the bonding surfaces. Use a heating
blanket to warm up the joint.
2. Fix the latch belts with side hooks, on both side of the pipe.
3. Use wooden blocks to prevent contacts between the came along jack
and the pipe.
and Yanbu (MARAFIQ)

PGIS-MOS-014
4. After ensuring the pipe sections are adequately supported and aligned
properly, check if the prepared bonding surface is clean and free from
dust, oil etc., if not, sand it with an emery paper and make it fresh prior
to application of the adhesive mixture. The prepared bonding surface
should not be touched with a bare hand or with a dirty hand gloves.
Insertion mark & Insertion depth:-

In order to check the actual insert depth of the spigot in the bell after
assembly of the joint, an insertion mark shall be scribed on the pipe
section containing the spigot end before application of the adhesive on
the bonding surfaces.
The insertion mark is scribed at a distance Y from the head of the spigot
(see fig. E1).
Y is derived from the following equation:

Y = Minimum insert depth + X (Eq. E1)
Where:
- For Minimum insert depth see table-1
- X = chosen value (mm).
Normally X is taken as a default value of 50 mm.
After assembly of the spigot in the bell, a check of the required minimum
insert depth of the spigot in the bell is performed by measurement of the
distance (Dist) from the head of the bell to the insertion mark (see fig. E2).
The correct insertion depth shall comply with the following requirement:
Dist <= 50 mm (Eq. E2)

and Yanbu (MARAFIQ)

PGIS-MOS-014
Occasionally, the value of X is not chosen 50mm. In that case X is an

appropriate value and the correct insertion depth then shall comply with
following requirement:
Dist <= X mm (Eq. E3)
5. Mix the adhesive containers for about 3 minutes until the mixture has
a uniform color. Adhesive components should not be mixed partially.
The expiry date of the adhesive components shall be checked before
using the product at all time.
6. Apply a thin, uniform layer of adhesive, approximately 0.5 mm thick,

and then apply another layer of approximately 1.0 mm thick. It is
important to ensure that no dust/sand or any other particles are mixed
with the adhesive or on the mixture spread of the bonding surface.
Notes:-
• The bonding process shall be performed directly after the sanding
is over. If not re sanding shall be carried out.
• The adhesive mixture will cure too fast if it is mixed above 40°C
and the work shall be carried out within the pot-life after mixing the
two components.
• Application & the pot life of adhesive kit at temperature above

40°C up to 55°C are acceptable if the joint is to be done within 10
minutes. An important thing to be noted is that the adhesive mix
should be spread on the pipe as fast as possible.
• A qualified technician shall perform the joining of adhesive bonded

joints.
7. Pull the pipe sections together by pullers.
8. Secure the alignment of the joint during insertion of spigot end into the
bell end.
9. Clean the excess quantities of adhesive formed around the joint. If

possible clean it from the inside. As shown in photo 7
10. Do not release the lever hoist until the bonded joint is self-cured.
and Yanbu (MARAFIQ)

PGIS-MOS-014
11. The bonded joint should not be disturbed under any circumstances
while the joint is curing.
12. Once the cement-bonded joint is self-cured, the puller can be

released. The temporary supports provided for the assembly or
alignment purpose shall remain in place until the joint is fully cured.
13. The adhesive bonded joint shall be considered accepted only after
passing the hydrostatic test.
and Yanbu (MARAFIQ)

PGIS-MOS-014
Curing
A. Ensure the bonded joint is self-cured by ascertaining the applied

cement is tack free.
B. Apply the heating blanket around the joint with the required
temperature as specified in Table 5. Close the ends of the pipe to
avoid any air blowing into the section. The duration of heating starts
from switching on to switching off the temperature regulator.
TABLE 5 - TEMPERATURE
Curing Temperature Duration
125 degree Celsius 2.0 hours
C. Once the heating process is completed allow the joint to cool down
naturally and remove all the fasteners and materials from the joint.
D. Mark the cured joint (unique color code) with a permanent marker or
with spray paint and to identify the uncured joint.
E. Each field joint shall be marked with a unique number, the joiner’s
identification (symbol, name, initials, or other unique identifier), date
and time of joining, and the date and time that heat curing started and
finished. The unique joint number and joiner’s identification should
also be recorded and reflected on the isometric drawing to be included
in the final turn over documentation.
F. Once the process is completed the joint is ready for hydrotest.
and Yanbu (MARAFIQ)

PGIS-MOS-014
Safety Precautions
The following safety precautions shall be taken when working with RTR
products.
a. While cutting and grinding the following personal protection shall be
used to avoid skin irritation and inhaling dust.
b. Dust mask covering nose and mouth.
c. Safety glass
d. Pair of suitable hand gloves
e. Overalls
f. Safety shoes
g. Safety helmets
h. When working with resin/hardener try to avoid direct contact with skin.
If skin has been in contact with resin/hardener wash with clean water
and soap before it become hard.
Acceptance Criteria
During performing adhesive bonded and lamination joint, all the criteria
detailed in the site ITP shall be strictly adhered to.
The joint shall be considered accepted only after passing the hydrostatic
test.
Repair
A. If any TB/TS joint is found to be leaking, cut the joint out and replace
it with a pipe piece. Connect this piece by two laminations. The repair
works are illustrated below.
and Yanbu (MARAFIQ)

PGIS-MOS-014
B. The same shall be done if the leak occurs on the pipe wall due to
impact damage.
C. In case of a superficial damage on the pipe, the following steps to be
followed. A superficial damage is a scratch within the resin rich outer
layer of the pipe.
a. Abrade the damaged area by using emery paper.
b. Use a brush to clean the area from dust.
c. Mix the Epoxy resin according to the recipe.
d. If it is necessary apply 1 or 2 layers of C-glass.
e. Apply the mixed resin on the damaged surface.
Note: All joints found to be leaking and/or damaged shall be reported to

the end user (owner) in order to give them an opportunity to inspect prior
to the repairs being made.
Site Storage for Cement Kits

The site storage of the cement kits should be maintained under an
ambient temperature of 300 Celsius and under a shaded area.
5.5 Backfilling
5.5.1 Area to receive backfill shall be free from water, trashes, debris
and other organic materials.
5.5.2 A minimum depth of 150mm clean sand bedding compacted to

90% standard proctor density.
5.5.3 After the installation and testing of underground pipes (by other
contractor) and is approved for backfilling by PGIS, a compacted
clean sand with a depth of pipe diameter plus 300mm minimum
shall be placed at every 150mm layer and compacted to 90%
standard proctor density.
5.5.4 Backfilling materials shall be from on-site stockpile or on the

borrow pit approved by Marafiq.
5.5.5 Backfilling shall be carefully and in a uniform manner, layer by

layer at 150mm and uniformly compacted. Compacting by water
and equipment shall begin only after the backfill has been
properly placed and the material shall be suitably moist.
and Yanbu (MARAFIQ)

PGIS-MOS-014
5.5.6 Attention shall be paid to the slope excavation grading before

start filling. Max allowed slope is 15%. Should greater slope
occur, step cutting is required to prevent sliding of filling material.
5.5.7 All compaction equipment shall be suitable for the entire lift
being compacted and the type of material to be compacted.
5.5.8 There shall always be a safe access way for entry and exit of
backfill material haulers and assign trained flagmen to look out,
direct traffic, and give signal to operators and drivers.
5.5.9 Backhoe operators should always take precautionary measures

in swinging and rolling their equipment to avoid hitting the
installed structures and existing structures as well as earthwork
crews working on backfilling.
5.5.10 To avoid rain water disturbances, all filling layers will have a
slope of 1-2% to allow free drainage. Adequate drainage system
shall be provided and maintained for the duration of the works.
6. INSPECTION
The contractor shall carry out the necessary inspection during the execution of
the work. It will include the various stages of the earthworks including the
excavation and compaction work. A Third Party Laboratory soil testing firm
approved by MARAFIQ, shall be responsible for testing onsite and any imported
fill to ensure compliance with required gradation consistency and density.
6.1 One standard Sieve analysis and one Modified Proctor test with
corresponding proctor curve shall be performed on every 1000cubic
meters. If there is a large variation in analysis, more frequent tests shall
be made.
6.2 The following in place density tests on compacted fill shall be performed.
6.2.1 Structural fills – one every 75 cubic meters.
6.2.2 Backfill and sub-base – every 150 cubic meters.
6.2.3 Road base and sub-base one every 75 cubic meters.

and Yanbu (MARAFIQ)

PGIS-MOS-014
6.3 At least one set of these density tests must be performed on every lift of
fill and further placement shall not be allowed until the required density is
achieved.
6.4 The number of tests shall be increased, if a visual inspection determines

that the moisture content is not uniform or if the compacting effort is
variable and not considered sufficient to obtain the specified density.
7. RISK ASSESSMENT
Please refer to the risk assessment.

MS For Excavation and Backfilling of Underground Fire Water Pipe Line PGIS

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Client / Owner: Contractor:

Power & Water Utility Company for Jubail

Project Title: Project No./Contract No.:

METHOD STATEMENT FOR EXCAVATION,

Project Title: Project No./Contract No.:

SECTION NO. TITLE SECTION

3 PERSONNEL DUTIES & RESPONSIBILITIES

4 TOOLS & EQUIPMENT

Project Title: Project No./Contract No.:

The procedure written in this Method Statement is as complete as possible; it is

3. PERSONNEL DUTIES AND RESPONSIBILITIES

3.2 Construction Manager

3.3 Site Engineer

Project Title: Project No./Contract No.:

 Program the work and explain the job to the concerned.

3.4 Supervisor & Foreman

3.5 QA/QC Inspector

3.6 Safety Officer

Project Title: Project No./Contract No.:

4. TOOLS AND EQUIPMENT

GRE / GRP Pipes

Project Title: Project No./Contract No.:

 Backing disc pad

5.1.3 Access road should be taken to consideration for the entrance

Project Title: Project No./Contract No.:

5.4 GRE / GRP Pipes Installation and Jointing

Project Title: Project No./Contract No.:

the damages are repairable, repair work shall be carried out in

Project Title: Project No./Contract No.:

Spigot & Bell Details

Spigot End (TS)- Figure 1

Bell End (TB) Figure 2

Table 1- Spigot & Bell details

Project Title: Project No./Contract No.:

Once the adhesive is mixed properly, apply a thin, uniform layer of

Project Title: Project No./Contract No.:

Project Title: Project No./Contract No.:

Insertion mark & Insertion depth:-

Y is derived from the following equation:

Normally X is taken as a default value of 50 mm.

Dist <= 50 mm (Eq. E2)

Project Title: Project No./Contract No.:

Occasionally, the value of X is not chosen 50mm. In that case X is an

Dist <= X mm (Eq. E3)

6. Apply a thin, uniform layer of adhesive, approximately 0.5 mm thick,

• Application & the pot life of adhesive kit at temperature above

• A qualified technician shall perform the joining of adhesive bonded

7. Pull the pipe sections together by pullers.

9. Clean the excess quantities of adhesive formed around the joint. If

Project Title: Project No./Contract No.:

12. Once the cement-bonded joint is self-cured, the puller can be

Project Title: Project No./Contract No.:

A. Ensure the bonded joint is self-cured by ascertaining the applied

Project Title: Project No./Contract No.:

Project Title: Project No./Contract No.:

Note: All joints found to be leaking and/or damaged shall be reported to

Site Storage for Cement Kits

5.5.2 A minimum depth of 150mm clean sand bedding compacted to

5.5.4 Backfilling materials shall be from on-site stockpile or on the

5.5.5 Backfilling shall be carefully and in a uniform manner, layer by

Project Title: Project No./Contract No.:

5.5.6 Attention shall be paid to the slope excavation grading before

5.5.9 Backhoe operators should always take precautionary measures