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UNDERGROUND WATER SUPPLY

Work Method Statement for Installation
Underground Ductile Iron Water Pipe

1.0 OBJECTIVE
This Method Statement is to define for methods of laying and installation
procedure for underground Ductile Iron water supply system

2.0 SCOPE
This procedure will define the method to be used to ensure that the pipe laying
work installed correctly and acceptable and shall conform to the Contract
Documents and Specification.

2.1

REFERENCES

a) Material and Workmanship Specification Section 140 Utilities Relocation

b) Material and Workmanship Specification Section 150 Water Supply for Station
c) Tender Drawings as provide

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Work Method Statement for Installation
Underground Ductile Iron Water Pipe

2.2

RESPONSIBILITIES
2.2.1 MANPOWER SCHEDULE
Item

Description

Project Manager

Site Engineer
Safety and Health

Personnel

Site Supervisor
Competent Machine

2.3

Operator

Mechanics

Competent Plumber

Job Function (Responsibilities)

To ensure overall works implementation in
order.
Prepare the Method Statement and related
submission, coordination and supervise
during installation at site.
To control and ensure the Safety and Health
is adhere at site
Coordination and supervising site activities.

Quantity
1

1
1

Operating the machinery

tba

Carry out maintenance work

tba

Conduct plumbing work

tba

MATERIAL, PLANT, MACHINERY AND EQUIPMENT

2.3.1 MATERIAL
No

Description

Quantity

Sluice valve

-tba-

Sand

-tba-

Ductile Iron Pipe PN16

-tba-

RC Pipe Sleeve class 2Z

-tba-

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Work Method Statement for Installation
Underground Ductile Iron Water Pipe

2.3.2 PLANT, MACHINERY AND EQUIPMENT

No
1.
2
2.
3
3.
4.
4
5.
5
6.
6
7.
9
8.
9.

Equipment

Description

Quantity

Backhoe

Excavation work

-tba-

Crane

Lifting work

-tba-

Hacker

To hack hard surface

-tba-

Diamond Road Cutter

Cut premix for road crossing

-tba-

Vibrator

For soil compaction

-tba-

Hand Tools

For general used

-tba-

Lorry

For material transportation

-tba-

Water Pump

For pipe testing purpose

-tba

Welding Machine

For pipe Jointing work

-tba-

To cut the pipe

-tba-

10. Power Driven Abrasive

Disc

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Work Method Statement for Installation
Underground Ductile Iron Water Pipe

WORK METHODOLOGY
3.1 PREPARATORY WORK
a) To ensure obtain start work approval from local authority and consultant.
b) To inform relevant authority and consultant for inspection of pipe material
during manufacturing before delivery.
c) To ensure the certificate and test reports either from SIRIM, IKRAM or other
recognized certification bodies available.
d) Areas where in to start permanent works shall be checked ensuring that they
are ready for the said installation.
e) Obtain existing services drawing, piloting record and carry out topographical
survey of the area and inform PDP and consultant for records prior to start any
excavation work.
f) Inform relevant authority to identify all isolating and scour valves affected by
the pipe to be relocated if required as well as valves located in the vicinity. It is
important to ensure that water scouring will not result in flooding of the area, in
particular the area during excavation and relocation work.

3.2 NEW INSTALLATION

3.2.1 Trench Excavation/Cutting of Premix Road
a) The trench shall be excavated by such method as allowed by relevant
authority and project specification for proper installation.

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Work Method Statement for Installation
Underground Ductile Iron Water Pipe

b) Trench excavation shall be carried out by such methods and to such lines,
dimensions and depths as per required in the specification to allow for the
proper construction of the works.
c) After identifying new pipe route, mark the entire road crossing and peg the
approved proposed alignment.
d) Excavate along the pipe route the trenches to the required depth and width.
e) Allowed to place excavated materials by the road-side. Excavated materials
shall be carted away to a waiting lorry and transported to dump site.
f) In cases where the trench depth exceeds 1.5 m, sheet pile wall or strutting of
trenchs wall shall be provided to prevent any untoward incident such as
cave in from happening.
g) Certain parts of the pipeline may be laid in ground with high water table,
especially in areas adjacent to the streams, river crossings and ponds.
Dewatering shall be carried out to ensure excavations and trenches dry for
the pipeline installation work to be carried in a safe manner during the
execution of the work.
h) The trench bottom should be true and even to give the barrel of the pipe soil
support for its full length.
i) Soft subgrade may prove a problem in swampy area or in loose sand. The
bottom of the trench can be improve by adding crusher run, lean concrete or
other approved method by consultant and authority.
j) Holes or pit for pipe bells should be provided at each joint but should be no
larger than necessary for joint assembly.
k) Public safety must be considered at all times. Excavated material from the
trench should be piled on the street side of the main, forming a barrier to
keep vehicles out of the trench.

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Work Method Statement for Installation
Underground Ductile Iron Water Pipe

3.2.2 Preparation for Pipe jointing

a) Before assembling the joint, the spigot of the pipe and interior of socket of the
adjacent pipe shall both be thoroughly cleaned.

b) The gasket shall be wiped clean and flexed and then placed in the socket with
bulb leading. The groove in the gasket must be located on the retaining bead
in the socket, and the retaining heel of the gasket firmly bedded in its seat so
that the heel of the gasket is not proud of the mouth of the pipe
c) To ensure the gasket fits evenly around the whole circumference, removing
any bugles that prevent the proper entry of the spigot end
d) A thin film of lubricant is then applied to the inside surface of the gasket which
will be in contact with the entering spigot. In addition, a thin film of lubricant
should be applied to the outside surface of the spigot end.

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Work Method Statement for Installation
Underground Ductile Iron Water Pipe

e) The spigot of the pipe jointed must be aligned and entered carefully into the
adjacent socket until it makes contact with the gasket. Final assembly of the
joint is completed from this position.

3.2.3 Laying pipe

a) To deliver designated site numbers of Ductile iron pipe
b) Cleaning the internal pipe cement lining, external bitumen wrapping and also both
ends of the pipe with cloth.
c) Loading the pipe line into the trench by crane or backhoe. The pipe should be
lowered progressively into the trenches using width belt or sling. When the main
is being laid downhill, for example, the pipes are occasionally laid with the bells
facing uphill for ease of installation
d) Dig a shallow bell hole in the trench bottom, lower the pipe and make up the joint.
Slide the sling to the bell end and lift slightly to provide clearance to slide the
encasement to the end. Small pipe can be pushed into the bell socket with a long
bar. Large pipe requires additional power, such as a jack, lever puller, or backhoe.

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Work Method Statement for Installation
Underground Ductile Iron Water Pipe

e) After the pipe is lowered, it shall be laid in the line and level. Check by using
levelling instrument, theodolite, etc
f) Joint assembly is completed by forcing the spigot end of the entering pipe past
the gasket, which is this compressed, until the first painted strip on the end of the
pipe disappear and the second painted strip is approximately flushed with the
socket face.
g) If joint is difficult to assemble, the spigot should be removed and rotated 90
degree before attempting to assemble a second time. If the joint is still difficult to
assemble, the spigot should be removed and the gasket examined.
h) At times when pipe laying is not in progress, the open ends of the pipe should be
closed with a watertight plug or other means approved by the owner. The plug
should have a means of venting and, when practical, should remain in place until
the trench is pumped dry. Air or water pressure in the pipeline must be released
prior to removal of the plug. Care must be taken to prevent pipe flotation if the
trench floods.
i) When pipe is cut in the field, bevel the plain end with a heavy file, an air-driven
grinder, or other suitable device and remove all sharp edges.
j) Either push-on joint or mechanical joint fittings may be used with push-on joint
pipe. The plain end of the pipe is provided with either one or two painted gauge
lines that can be used to determine if the plain end has been properly positioned
in the bell socket. The pipe manufacturers instructions regarding the location of
these lines after assembly should be followed.

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Work Method Statement for Installation
Underground Ductile Iron Water Pipe

k) After the new pipe line is completed, both ends capped with blank flange joint and
ready to fill in water for Testing and Commissioning.
3.2.4 Pipe cutting
a) Where flexible joints are to be made, the cut ends must be trimmed with a file or
grinder to remove the burr formed during cutting and a chamfer must be provided.

b) A Power Driven Abrasive Disc can be used and is suitable for all sizes. There is
no need for adjustment to suit pipe size or to attach machinery to the pipe. The
abrasive discs are fitted to suitable hand held power tools usually driven by
compressed air or small internal combustion engines.

c) After cutting the pipe check the cut end and where is found to be oval, locate and
mark the major axis. Measure the length of the major axis. Only where this
exceed the dimensions specified in the table, will ovality correction be required
prior to jointing.

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Work Method Statement for Installation
Underground Ductile Iron Water Pipe

d) Reciprocating Power Saws also will be used for cutting ductile iron pipe at the
workshop where power supply is available.
e) The pipe DN<300 the external diameter (measured circumferentially) enable
assembly of the joint over a minimum of two thirds of pipe length from the spigot
end when the pipes need to be cut on site. For pipes DN>350 the same applies to
a percentage of the pipes.
f) For the pipe DN>350 the diameter shall comply with the limits specifie in the table
below :

g) After cutting the pipe check the cut end and where is found to be oval, locate and
mark the major axis. Measure the length of the major axis. Only where this
exceed the dimensions specified in the table, will ovality correction be required
prior to jointing.
h) To ensure that the cut spigot must be chamfered.

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Work Method Statement for Installation
Underground Ductile Iron Water Pipe

f) For the K type socket pipe jointing. The major axis of the spigot end of a K
type joint pipe is indicated by the short white line painted on the spigot at
works.
g) Measure the length of the major axis, only where this exceeds the appropriate
dimension specified in the above table will ovality correction be required prior
to jointing.
3.2.5 Backfilling
a) Backfilling should closely follow the joint of the pipe so that the protective coating
should not be subsequently damaged.
b) Material harmful to the pipe line shall not be used for the backfilling
c) Refilling shall be done as per project specification
d) The filling of the two side of the pipeline should be carried out simultaneously
e) Where the timbers are placed under the pipeline to aid alignment, this shall be
removed before backfilling.
3.2.6 Testing and Commissioning of Overall System
a) The water pressure test will carry out with pressure pump until 22.5 bar for
duration of not less than 7 days. More water should be pump for into the section
to raise the pressure slowly in increment of 1 bar with a pause of one minute in
each increment. Should any appreciable drop in pressure be noted during any of
this pauses the test should be stopped until the cause of the pressure drop has
been investigated and rectified
b) The pressure test should consider passed when the pressure gauge show no
more reduction.
c) The leaking test shall be follow with the pressure pump until 15 bar at the
duration of 24 hour. The leakage test shall consider to have been passed if the

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Work Method Statement for Installation
Underground Ductile Iron Water Pipe

water pump into the section of the main does not exceed the allowable leakage
calculated.
d) After the test pass, the new pipe line will carry out the sterilizing. The water will be
released after the sterilizing test pass.
e) Every section pipeline shall be tested with representative of Employer
representative and relevant authority for the main pipeline testing.
f) Then the new Ductile Iron pipe is ready for final connection and energize.

3.3

Traffic Management & Control

The TMP shall be carried out in accordance to the approved TMP plan by the
PDP and relevant authorities.

a.
(i)

General
WPC shall appoint a competent TMP Contractor to carry out the TMP
throughout the area. The TMP Contractor shall also assist the WPC for the
necessary submission and obtain authorities approval / permits prior to
implementation of the TMP.

(ii)

WPC shall also maintain own TMP maintenance team to supplement the
appointed TMP Contractor in carrying out the duties.

(iii)

Traffic study shall be conducted for current daytime morning and evening
peak flows along existing road/highway to ensure whether daytime lane
closure/traffic diversion is with minimal disruption. If traffic is not ok for
daytime TMS, to consider night work with night TMS.
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Work Method Statement for Installation
Underground Ductile Iron Water Pipe

(iv)

If required due to lane closure, highway/road to be widened or realigned or

temporary diversion introduced in order to maintain par with the existing
facility.

(v)

Traffic Management Plan (TMP) shall be submitted

to relevant authorities

for all necessary approval.

(vi)

Once approval obtained, TMP is executed as per the provision and be

maintained throughout the construction period.

(vii)

For night work TMS (if any), approval shall

be

obtained from relevant

authorities i.e. JKR, DBKL, KLCH, Traffic of RMP, MHA and relevant
concessionaires.
(viii)

Submit any reports/document as per provision and requirement by relevant

authorities.

SAFETY AND HEALTH

4.1

Job Safety & Health Analysis

Job Safety & Health Analysis shall be carried on the project site. The hazard in a
particular activity and the control measures implementation shall be briefed to the
workers during safety induction session, toolbox talk and JSA Briefing. Please
refer to attached Appendix 7.2.1

4.2

Information to Personnel
4.2.1 All workers employed in the project must have CIDB Green Card, KVMRT
passport.
4.2.2 All lifting activities, WPC shall provide a Lifting Supervisor that obtains
training from KVMRT Training Centre.
4.2.3 All temporary structure shall provide a Temporary Work Coordinator.
4.2.4 All new workers and staff to attend the Safety Induction Course before
commencing works site and attendances shall be recorded in an induction
list.
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Work Method Statement for Installation
Underground Ductile Iron Water Pipe

4.2.5 All site personnel shall wear proper Personnel Protective Equipment (PPE)
Safety Helmet, Safety Vest, Safety Boots, water boots, etc.
4.2.6 Monthly Safety Meeting shall be held with all the contractors related to the
works.
4.2.7 All workers to attend the weekly toolbox meetings conducted by the Safety
Manager / Safety Officer held at site and attendances shall be recorded.
Highlight on the machineries and lorries movement to prevent the workers
from getting stuck and accident happen at site.
4.3

Emergency Arrangement
4.3.1 Please refer to appendix 7.2.2 for Health, Safety and Environment
Emergency Response Team and Flow Chart.
4.3.2 The Organization Chart, List of Emergency Contact Person and relevant
authorities with their contact numbers shall be showed in the Notice Board.
4.3.3 The emergency situations which may occur are shown in the table
(Appendix 7.2.4) for Job Safety and Health Analysis. The level of risk or
severity of the accident dictates the emergency level.
4.3.4 In the event of emergency, the site management staffs must evaluate the
situation and commence the necessary procedures as follow:

Raise the alarm.

Stop works.

Remain composed.

Make sure notifications of emergency or evacuation are in place for

all workers surrounding the vicinity.

Make sure all workers are assembled at designated assembly point.

Make sure first aid kits are prepared at assembly point.

All workers are told not to leave the assembly point until clear sign is
issued.

Headcount shall be conducted.

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Work Method Statement for Installation
Underground Ductile Iron Water Pipe

4.4

First aiders shall attend to the injured workers.

Prepare assessment reports for the losses.

Permit Requirement
Some of the working arrears require permission for the work commencement and
for certain duration and limitation by relevant authority. It requires application to
the authority or relevant parties and the WPC shall notify the PDP. Permit to start
work shall be obtained before any commencement of work.
For night work, the area of work shall be adequately lit of facilitate works and
movements on site. Warning lights, directive signs, reflective aids and barriers
shall be placed at suitable location to forewarn all potential hazards. Work permit
shall be applied to relevant party and notify WPC Safety Officer and PDP
representative before any commencement of work.

ENVIRONMENTAL ISSUES
5.1

Environmental Aspects, Impacts & Control Measures

i.

Relocation of Underground Utilities

ii.

Operational of Toilet and rest area

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Work Method Statement for Installation
Underground Ductile Iron Water Pipe

QUALITY ASSURANCE & QUALITY CONTROL

6.1

Contractual Requirements
Materials and Workmanship Specification, Section 140: Utilities Relocation
Materials and Workmanship Specification, Section 150: Water Supply for Station
SSP-MRTC-GENE-OVPR-SPC-03140
SSP-MRTC-GENE-OVPR-SPC-03150

6.2 Inspection & Testing

Refer to Inspection and Test Plan
TRC/PQP/SSP-MRT-V204/ITP

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Work Method Statement for Installation
Underground Ductile Iron Water Pipe

6.3 Follow up & Evaluation

Request for Inspection (RFI)
To monitor using Quality Checklist

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