METHOD OF STATEMENT
PROJECT:
MENAIK TARAF JALAN PERSEKUTUAN FT 237
(DARI EXIT CHUKAI MENUJU KE FT 003)
KEMAMAN TERENGGANU
MSCL PIPELAYING
WORKS
Prepared By: Reviewed By: Approved By:
Name : Name : Name :
Date : Date : Date :
METHOD OF STATEMENT
PROJECT Menaiktaraf Jalan Persekutuan FT237 (Dari Exit LPT 2 Menuju Ke FT003) DOC NO:
Kemaman Terengganu PMJE/DC/01/MOS
SUBJECT MSCL Pipelaying Works REV: 0
1.0 INTRODUCTION
This method statement briefly describes the laying works for MSCL pipe and associated works. In
principle, the works can be sequenced as below:
i. Excavation Works
ii. Pipe Laying Works
iii. Welding Works
iv. Backfilling Works
v. Pipe Testing Works
2.0 MACHINERY USED/ REQUIREMENT
In order to satisfactory carry out the pipe laying works, the following machineries or requirement
shall be used:
i. Excavators/ Backhoe
ii. Dumping Lorry
iii. Water Pump
iv. Mobile Crane (For Unloading Material)
v. Cutting Equipment
vi. Welding Machines
vii. Electrical Generator
viii. Lifting Tools – Belts, Chain block Etc
ix. Suction Fan (For Internal Welding)
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METHOD OF STATEMENT
PROJECT Menaiktaraf Jalan Persekutuan FT237 (Dari Exit LPT 2 Menuju Ke FT003) DOC NO:
Kemaman Terengganu PMJE/DC/01/MOS
SUBJECT MSCL Pipelaying Works REV: 0
3.0 EXCAVATION WORKS
The excavation for MSCL pipe will be programmed closely with any adjacent works, which could be
carried out concurrently. The excavation depth for the said pipe routine would be based on the invert
of pipe and construction drawing required.
In general, the pipes excavation works can be categorized into shallow trenching. For shallow
trenching, excavator/ backhoe is to be used for excavation and pipe laying purposes. The trenching
width is to be as per construction drawing and specification. Whenever the ground condition is soft
or swampy, a timber shoring system using steel plate and sheet pile strut to be installed, to avoid
earth collapse and water pump is standby for dewatering the tranches while the laying of pipes
involves deep excavation, safety should be taken during excavation. Whenever it is necessary, excess
earth shall be removed away from the edge of trench to prevent collapse of earth at trench edge.
Additional sheet piling, strutting and shoring shall be done where excavation is immediately adjacent
to existing structure /services.
4.0 PIPE LAYING WORKS
The materials, sizes and classes of the MSCL pipes shall follow the specification and construction
drawings. During material delivery, thickness test shall be executed to make sure the materials follow
the specification. The thickness test will be using the vernier calliper and will be recorded.
During pipe laying works, a dumpy level and wooden pole should be used to control the excavation
depth, sight rails may also be used to control the levels.
Trench will be excavate based on the jointly pegged out alignment to the required level. Suitable
material from trench excavation will be stockpiled or used for filling depending on site conditions and
work progress. The base of trench would be prepared accordingly to the type of bedding required
before pipe being laid.
During pipe laying, temporary hold-downs/ backfills maybe required at section of pipe laid to prevent
“flotation” of pipes laid due to water pressure, until the pipe trench has been properly backfilled.
Pump shall be used to keep excavation trench dry when ground water seeps out and during wet
weather.
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METHOD OF STATEMENT
PROJECT Menaiktaraf Jalan Persekutuan FT237 (Dari Exit LPT 2 Menuju Ke FT003) DOC NO:
Kemaman Terengganu PMJE/DC/01/MOS
SUBJECT MSCL Pipelaying Works REV: 0
5.0 WELDING WORKS
Welding is carried out on the joints when the level and alignment of the pie are checked and
confirmed against the approval levels and alignment. Proper ventilation such as suction fan shall be
provided inside the pipe when carrying out internal welding works.
Mild steel spigot and socket ended pipe above 700mm diameter shall be jointed by means of an
internal and external circumferential metal arc weld at each point (refer BS EN10311 type 1/type2).
Before placing the pipes together, the portion of spigot and socket to be welded shall be cleaned to
a bright metallic finish. The spigot end shall be placed on the socket and forced inside so that spherical
surfaces are in contact and the average gap between the pipe at the end of the spigot shall not exceed
1.5mm. The weld shall be on convex, full filler type for lap welded made manually by metal arc process
using welding electrode.
For welded collar joint, where plain ended and mild steel special are to be jointed by a mild steel split
collar, the pipe ends and collar shall be cleaned to a bright metallic finish. The collar shall then be
placed on the ends of pipes so that the space between the pipes ends shall be about 25mm from
centre line of the collar. For size above 700mm in diameter, the collar shall be jointed to the pipe by
mean of an internal and external circumference weld. The weld shall be of the convex full fillet type
for lap welded made manually by metal arc process using the welding electrodes. Each time the arc
is started it shall be manipulated to obtain complete fusion of the weld metal with the pipe metal and
any previously deposited weld metal. Before welding over any previously deposited weld metal all
slag shall completely remove and the adjacent pipe metal shall be cleaned by wire brushing.
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METHOD OF STATEMENT
PROJECT Menaiktaraf Jalan Persekutuan FT237 (Dari Exit LPT 2 Menuju Ke FT003) DOC NO:
Kemaman Terengganu PMJE/DC/01/MOS
SUBJECT MSCL Pipelaying Works REV: 0
AIR TEST AND DETECTION OF LEAK
Upon completion of the weld, air test shall be conducted on these welds for pipe sizes larger or equal
to 700mm diameter. The internal air space of the welds shall be pressurized to 2.5MPa (25 Bar) and
maintained for a period of ten minutes (refer to BS EN 10226-1). Soap water shall be applied onto the
internal and external weld to detect location of leak should the air pressure within the air space drop.
The leaking areas shall be rectified and air test shall be welded.
COMPLETION OF SHEATING AT WELDED JOINT
After the welded joint passed the air test, the external sheating shall be completed to ensure
continuity of protection along the pipeline.
Bare metal shall be thoroughly cleaned to a bright metallic finish and it shall be immediately coated
with a primer solution, the primer shall be applied cold by brush.
As soon as the primer has set the sheating shall be completed by running hot bitumen into a metal
mould placed over the joint and overlapping the sheeting by 75mm on either site of the joint (Refer
to BS EN 10300)
INTERNAL MORTAR PROTECTION
The internal side of the joint shall be protected by cement/ sand mortar in the correct proportions.
The mortar shell be applied from bottom of the joint and work upwards towards the top of the joint.
The mix design ration for internal mortar protection is: Cement: 1, Sand: 2.
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METHOD OF STATEMENT
PROJECT Menaiktaraf Jalan Persekutuan FT237 (Dari Exit LPT 2 Menuju Ke FT003) DOC NO:
Kemaman Terengganu PMJE/DC/01/MOS
SUBJECT MSCL Pipelaying Works REV: 0
6.0 TRENCH BACKFILLING WORKS
The trench shall be backfilled as follow:
i. Below good/ normal ground
- With sand to 150mm above the top of the pipe. The rest of the trench shall be filled with
compacted suitable material to the finished ground level.
ii. Below poor/ soft ground
- With sand to 300mm above the top of the pipe. The rest of the trench shall be filled with
compacted suitable material to the finished ground level.
iii. Below road/ track
- From top of pipe to finished level of road/ track with compacted sand except the last
layer which shall be filled with the same material and thickness as the original road
pavement/ track
There is no pipe trenching to be left opened by the end of the working day and/ or if the backfilling
works is not complete. A bund around the trench is to be built to prevent water from flowing into the
pipe trench and to avoid earth entering the pipe opening.
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METHOD OF STATEMENT
PROJECT Menaiktaraf Jalan Persekutuan FT237 (Dari Exit LPT 2 Menuju Ke FT003) DOC NO:
Kemaman Terengganu PMJE/DC/01/MOS
SUBJECT MSCL Pipelaying Works REV: 0
7.0 PIPE CROSSING USING REINFORCED CONCRETE CULVERT
i. Section A as shown in the sketch above to be cut with required depth and width as specified.
Section B on the other side to be opened for traffic with proper TMO installed along the road
prior to cutting section A
ii. Once excavated level reached and confirmed, sand to be laid on the trench bed to require
level.
iii. Reinforced concrete culvert to be laid into the trench, level and alignment of the pipe to be
checked and inspected before the culvert to be backfilled with sand till top of pipe. Once
completed, the trench to be backfill with compacted crusher run to required level or
according to JKR standards
iv. The end of the culvert to be temporary closed with suitable plywood or steel plate to ensure
no earth from entering the culvert.
v. Section A to open for traffic once backfilling and section B can proceed (Refer step 1 until 3).
vi. After section B complete backfilling, the road will be opened to traffic.
vii. Roller will be put inside the culvert and put the pipe above it and the pipe will be push by the
excavator until the end of the pipe.
viii. The pipe will be joint with another pipe and will be carry out welding work. Once the welding
completed on the joint, the pipe once again will be pushed by the excavator onto the culvert.
ix. Repeat step 7 and 8 until the pipe cross the culvert.
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METHOD OF STATEMENT
PROJECT Menaiktaraf Jalan Persekutuan FT237 (Dari Exit LPT 2 Menuju Ke FT003) DOC NO:
Kemaman Terengganu PMJE/DC/01/MOS
SUBJECT MSCL Pipelaying Works REV: 0
8.0 PIPE TESTING WORKS
In principle, the MSCL pipe testing shall include the following:
i. Water Pressure Test
ii. Water Leakage Test
iii. Pipe Flushing & Disinfection Test
The above-mentioned test is suggested to be carried out after completion of backfilling and the pipe
have been completely laid from one section to another section
WATER PRESSURE TEST & LEAKAGE TEST
i. Plug the MSCL pipe (pipe outlet) with suitable end plug, e.g. End cap.
ii. The MSCL pipe will be filled with water and period not less than 7 days will be allowed for
absorption, after which water will be added from a measuring vessel at intervals of 5 minutes
and the quantity requirement to monitor the original water level noted.
iii. In order to measure the water pressure, the gauge shall be installed at high end of MSCL pipe,
e.g. at the outlet of pipe.
iv. The water inside the MSCL pipe to be pressurized up slowly in increments of 1 bar with a
pause of one minute between each increment, to the maximum pressure (22.5 bar) for
pressure test to be hold for 10 minutes.
v. Upon completion of the pressure test, the result shall be recorded and the leakage test shall
commence after that by reducing the pressure to the maximum permissible (15 bar) working
pressure as specified in the specification. If these conditions are not satisfied a thorough
inspection of the section of the main pipe shall be made. All defects shall be repaired and the
test shall be repeated.
vi. The water inside the pipe shall be kept for 24 hours
vii. The water pressure shall be checked after that.
viii. If the water pressure is found drop dropped, refill the volume of water in order to achieve
water pressure.
ix. Record the volume of water and compare with the specification. The leakage calculated as
0.34 litre per cm of pipe diameter per km of pipe per 24 hours per 1.0 bar of water pressure.
x. All test results will be recorded in a standard form as attached.
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METHOD OF STATEMENT
PROJECT Menaiktaraf Jalan Persekutuan FT237 (Dari Exit LPT 2 Menuju Ke FT003) DOC NO:
Kemaman Terengganu PMJE/DC/01/MOS
SUBJECT MSCL Pipelaying Works REV: 0
For the water pipe laying, after the completion of pressure and leakage test, the pipe shall be
arranged to carry out for disinfection and flushing is required by the authorities. The test was
descripting as below:
i. First to clear the pipe line and to fill in the solution of chloride of lime containing at least 40
parts per million of chlorine.
ii. After the pipe being filled with chlorinated water, it should be closed and left minimum 24
hour.
iii. After 24 hours, collect at least 3 outlet locations or more of the water sampling and a site
chlorine residual test shall be carried out. The result shall be at least 0.2mg/l.
iv. After the result being satisfactory to the requirement, a flushing will be carried by using clean
water.
