METHOD OF STATEMENT For HDPE Pipe Installation
METHOD OF STATEMENT For HDPE Pipe Installation
METHOD OF STATEMENT For HDPE Pipe Installation
Contents
1. Location & Description of the project..............................................................................................3
2. Scope of works Covered....................................................................................................................3
3. Reference Documents........................................................................................................................4
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Warning tape laying.
Final dressing and Formation Level Preparation.
3. Reference Documents
Contract Documents
Construction Drawings / Shop Drawings
Project Schedule / Construction Program
Project Special Specification
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Electrician - To prepare required power connection and illumination.
Foreman- To direct work for the workman.
Operators-To operate excavators, Dozer, Etc.
Drivers -To drive the vehicles required for excavation operation
Helper - To help the skilled workman.
Riggers- To align pipe
Welders-For welding
6. Subcontractors Utilized
The Criteria for fixing the subcontractor will be mainly as per the requirement of
Project. The Sub Contractors will be analysed according to their previous work experience
of the similar nature, their Company profile, their ability to execute the work as per the
project specification and up to the satisfaction of the Client. More weightage will be given to
the Subcontractors who are registered with the SME.
Before the deployment of every Subcontractor, we shall submit their relevant document to the
Client for their approval. We shall also insist the Subcontractor to get themselves registered
with Salalah Free Zone Company S.A.O.C. Once the subcontractor is approved by the Client,
the necessary HSE induction will be given to them to understand them the requirement of the
Client as well as ours.
Excavator
Plate compactor
JCB
Hand saw / Hack saw
Files round/flat
Measuring tape
Sprit level, Plumb, Chalk line
Grinding Machine.
HDPE (High Density Polyethylene) butt fusion welding machine
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8. Prior activities to be completed
8.1 General
Request for Inspection form will be raised to Client before commencing of
work. All necessary documents such as checklist, key plan, approved
relevant drawing as reference, survey report, etc. will be attached in the
Request of Inspection before submitting. Plastic barriers will be placed
around the area to be excavated. Access to the excavation area will be
restricted and controlled by Foreman during all activities.
Survey Works and Marking
The surveyor shall set-out the approved levels at site before
commencement of works, the same shall be checked and verified by the
engineer’s representative to site.
9. Methodology
1.1 Receiving materials:
The material received is as per approved MAS.
The quantities are correct as per the purchase order and delivery note.
The materials are in the manufacturer’s original packing.
Once the material is received at the site, MIR shall be raised for material inspection
and obtain approval to use at site.
If material observed to be not as per approved MAS, the same will be removed from
site within 24hrs.
1.2 Handling / Storage and Transportation of materials at Site:
Prior to unloading, it shall be ensured that the stack area is free from sharp
projections, stones or other protuberances.
Pipes may be off-loaded from the vehicles manually.
Care shall be taken to avoid damage of spigot and socket during transit, holding and
storage. Pipes shall never be dragged on bare ground.
Pipes shall not be stacked in large random piles.
Socket pipes and those with anchor seal joints shall be stacked in layers with sockets
placed at alternate ends of the stack and with the sockets protruding apart.
For ideal storage, pipes shall be uniformly supported and properly protected with
Tarpaulin sheets around to prevent direct exposure to sunlight.
Each layer of pipe stack shall not exceed 1.5 meters in height.
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When loading pipes on to vehicles, care shall be taken not to allow them to come in to
contact with any sharp corners such as loose nail heads as pipes may be damaged by
being rubbed against these during transit.
1.3 Pre-Installation:
1.3.1 Trench Preparation and Removal of Existing Pipeline & Air Valve Chamber
Centerline marking and excavation dimensions shall be done as per the Approved
drawing including clearance from the face of any structure For Removal of Existing Pipe
Line and within necessary working space.
Adequate signage shall be placed near the excavation.
Remove the existing Pipeline from the Trench.
Removing of Air Valve Chamber.
Trench inspection shall be carried out as Per approved Excavation MST&ITP
The trench bottom shall be carefully examined for the presence of hard objects, rocky
projections or large tree roots and shall be trimmed to an even finish.
Depth of bedding shall be as per approved drawing.
It shall be ensured that the Bedding material is free from large stones and granular
material crushed stone (Aggregate)
Initial filling material shall be crushed stone (Aggregate)
Butt heat fusion welding of HDPE pipes shall be in accordance with DVS 2207-1.
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The butt-welding method is the most commonly used method of joining HDPE pipes. No extra
material is used instead the surface to be joined is heated by means of a heating plate.
The melted surfaces are then pressed together and will fuse into each other forming a strong
joint. The strength of the material is based on the fusion of atoms.
Welding beads shall not be removed and are usually kept as a visual reference for the
welding quality.
Welding machines (heat fusion machines) have strong body frames, guide rods for the pipes,
a pipe end planer, and an electric heater plate.
The welding area shall be protected from unfavorable weathering influences (e.g., wind, rain,
high humidity levels, etc.).
The preferred ambient working temperature for welding is in the range of +5°C to +45°C. If
necessary, protecting the welding area with a tent or similar arrangement shall be arranged to
maintain a constant environment in the working area.
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All pipes shall be laid in trenches at the required depth below the surface as per approved
shop drawing and road details.
Pipes crossing the roads shall be protected fully and embedded in the sand.
All pipes, fitting etc. shall be carefully lowered into the trench with suitable equipment in a
manner that will prevent damage.
When work is not in progress, the open ends of the laid pipeline shall be securely plugged.
Install all pipes in accordance with the manufacturer’s recommendation, fixing each item
firmly in position, level, plumb, and properly joined.
To prevent the pipeline from floating, the backfill must be sufficient to prevent the pipe from
being exposed to foreign objects.
Any pipe that has floated must be removed from the trench and reinstalled in a dry trench.
13.3.5 Cleaning
The joining faces of the HDPE pipes, hdpe pipes fittings, tools, and the heating element must
be clean and free from contaminations (oils, fats, grease, chipping, etc.). The paper used for
cleaning must be unused, absorbent, non-fraying, and undyed.
The element must be cleaned with paper before every welding operation. No residues of
cleaning agent or paper shall remain on the element.
The hdpe pipe ends to be joined shall be scraped immediately before the beginning of the
welding.
The heating element temperature shall be checked before the start of the welding pipe work.
A high-speed thermometer shall be used to control the element temperature prior to each
welding process.
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Control measurement must happen within the area of the heating element which corresponds
to the pipe surface. In order to achieve a thermal balance, the element should be used not
before 10 minutes after reaching the required temperature.
For optimal welding, the element shall be cleaned with unused, absorbent, non-fraying, and
undyed paper prior to the start of every welding process. The non-stick coating of the element
must be undamaged in the working area.
In addition, during the HDPE pipe work welding process by slow movement of the workpieces
occurs a movement pressure or movement power which can be seen on the indicator of the
welding heat fusion machine and should be added to the first determined joining power of
joining pressure.
The nominal wall thickness of the parts to be welded must correspond to the joining area.
Before clamping the pipes in the welding heat fusion machine, they must be aligned axially.
The areas to be welded should be cleaned immediately before the welding process with a
clean, fat-free planner tool so that surfaces are aligned in the clamped position. The following
table provides the permissible gap widths under adapting pressure:
Pipe diameter, d
Permissible gap width (mm)
(mm)
≤355 ≤0.5
1000 ≤2.0
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Together with the control of the gap width, any misalignment of HDPE pipes should also be
checked.
The misalignment of the joining areas to one another should not overstep the permissible
degree of 0.1 x wall thickness on the pipe outside or on the table respectively.
Prepared and cleaned welding surfaces shall not be left open for an extended time, nor shall
they be touched by hands otherwise a renewed preparation (cleaning, scraping, etc.) is
necessary.
Place the heat fusion machine on even, horizontal, and dry ground.
Check that the right sizes of clamps are fitted into the machine.
Place the supports line up by eye.
Pull the pipe into fixed clamp, longer pipes always should be on the fixed pipe clamp
side.
The pipe end should be 50mm outside of the pipe clamp to allow trimming and
heating.
Adjust supports to ensure the pipe is in line both vertically and horizontally with the
machine.
Lift upper pipe clamp onto the machine. Screw-on pipe clamp nuts. Upper bolts
protrude through holes in the upper pipe clamp, bottom then aligns automatically.
Tighten the pipe clamps nuts by hand or socket spanner.
Load shorter pipe into movable pipe clamp side. The pipe must be aligned so that
when ends are not straight, they initially are loaded into the machine point to
facilitate straight trimming.
Check the position of the movable pipe clamp. The clamp should be in a fully open.
position to allow proper heating and welding, if the clamp is in a closed or nearly
closed position the moving range of the clamp (hydraulic cylinders) is not enough
and the forces during welding will load the body frame of the machine only.
Adjust supports to ensure the pipe is in line both vertically and horizontally with the
heat fusion machine.
Tighten pipe clamp nuts. Pipe clamp nuts should be tightened to give coarse
alignment of pipe ends. Bottom nuts will move pipe end up. Top nuts will move pipe
end down.
Adjust pipe ends for fine alignment with the centering blocks.
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Place planer into the machine. Ensure planer is the incorrect rotating direction to cut.
Lock planer into place with planer holder.
Start the planer motor.
Move movable pipe clamp until it touches the planer’s face.
Trim the pipe ends (Safety measures while trimming are included in the health and
safety section).
Allow hydraulic pressure to fall to “0” zero. Planer will be rotating freely.
Open hydraulic valve.
Open the machine.
Turn off the planer motor.
Remove the planer.
Remove cuttings from pipe ends. Only use a cloth to remove cuttings from inside the
pipes.
Close machine and check alignment of end faces.
Repeat trimming if pipes faces are not properly aligned face to face.
Close movable pipe clamp side.
Note and record friction force (also called “drag force”).
The fusion welding process requires the pipe surfaces to be joined, to be warmed up to the
required welding temperature by means of a heating element prior to them being joined
together under pressure. The element temperatures are listed in the following table.
Generally, the aim is to use higher temperatures for smaller wall thicknesses and lower
temperatures for larger wall thicknesses.
PE PP PVDF ECTFE
Heating
Element 200 up to 200 up to
232 up to 248 275 up to 285
Temperature 220 220
(Degrees C)
Check the temperature and the spread of temperature over the entire heater plate by means
of a surface thermometer. Variation of the temperature over the surface should not be more
than 10 °C from the set value.
Maintain the pressure throughout the cooling period (t5). Cooling should not be accelerated
for instance by water or air. Proper cooling time as per welding parameters under pressure
must be ensured to create a strong joint.
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13.3.12 Removal of Pipes
The construction length of the neck must be taken into consideration when welding
necks are joined to the pipe using the butt-welding process.
For short welding necks that do not have sufficiently long cylindrical ends for clamping,
welding machines with a neck holder must be used, if possible. In particular, this applies
whenever, due to constraints, the loose flange has to be pushed over the neck before
welding.
When integral flanges are to be welded, it must be ensured that the bolt holes are
arranged symmetrically to both main axes of the pipe.
If possible, butterfly valves that are adapted to plastic pipes and whose disc is adjusted
to the reduced inside diameter of the pipe shall be used.
Loose flange, welding neck, integral flange, seal, and the loose flange shall be aligned
centrally with the pipe axis. When aligning the seal, it must be checked whether the seal
dimensions conform to the outside and inside diameters of the welding neck.
Before the bolts are tightened, gasket faces of the welding neck, neck bush, or the
integral flange must be located parallel to one another and must be in close contact with
the seal.
After completing a welded joint, a unique number shall be given for traceability and
recording purposes. The given number shall be clearly visible and must be written
adjacent to the welded joint. This number shall allow the tracing of the welder name and
the date of the weld on the welding log sheet.
The welding log sheet is prepared by the qualified welder and checked by the
responsible QC Engineer and/or Project Engineer.
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13.3.15 Inspection of HDPE Piping, Fittings, and Joints
Welding is attended to and inspected visually for the size and evenness of the bead as well
as the matching of pipe ends to each other.
1.4 Testing
a) Pre- Testing
Inspection shall be carried out as per the sequence referred in Inspection Test plan for
installation and testing of sewage network system – UPVC Pipe & Fittings during
construction & before backfilling.
b) Air Testing
Air testing shall be done as per clause no 8.2.3.9 of OMAN standard specification volume no
3.
As soon as practicable after a length of pipe has been completed, it shall be subjected to an
air test to BS EN 1610
Length of pipe shall be plugged and sealed and air pumped into the pipe by approved
method.
We shall allow 5 minutes for stabilization of air temperature and adjust pressure to 100 mm,
the section will not be considered satisfactory if the air air pressure fails from 100 mm to 75
mm head of water in 5 minutes or less
Failure to pass the air test is not conclusive and if no leakage can be traced by externally
application of soapy water to all sealing areas.
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In case of no leak, clearance shall be obtained from Engineer for top bedding and further
backfilling.
EMERGENCY SERVICE
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SL EMERGENCY CONTACT DEPARTMENT/ CONTACT
NO PERSONS COMPANY NUMBER
1 JULIUS SNCHEZPASIA TATWEER 99286578
2 SAIF AL AMRI TATWEER 98050876
3 PETER AWAD AAW & PARTNERS 96213306
4 SUNIL KUMAR ALHASHEMI & AL 93213580
RAWAS
5 L.K. PRADHAN ALHASHEMI & AL 91772739
RAWAS
6 PRAMODKUMAR ALHASHEMI & AL 93213581
RAWAS
7 HANEEFA ALHASHEMI & AL 93211994
RAWAS
8 DURAI BABU ALHASHEMI & AL 99096569
RAWAS
PERMIT REQUIREMENTS
DEPARTMENT UTILITY
TANWEER ELECTRICITY
MARAFIQ WATER
OOREDOO TELECOM
ROP TRAFFIC
SEZAD PERMITS
ENVIRONMENT ENVIRONMENT
HERITAGE ARCHEOLOGICAL
13. Appendix
Hazard Identification, Risk Assessment & Determining Controls
(HIRADC)
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