engineeringconstructionmethodsguidelinescbs_161 by 8V4xjYtD

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									A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              1 of




                                                                                                  Civil Engineering
                                                                              Buildings Practice
Construction Method
Statements
                                                                General Activities
P Eng Suraj Singh



Contents index
 For navigation please click these pasted hyperlinks
Construction Method Statements for various
activities within civil engineering for plants works
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              2 of



Site Preparation & Earth Work                             PROTECTION                   OF       EXISTING             RE-ROUTING OF 33KV CABLES
                                                          SERVICES                                                   Concrete Pipe Culverts
CONCRETING TO WALLS OF
                                                          CONCRETE                                     PIPE CULVERT CROSSINGS TO AVENUE
CENTRAL CONTROL BUILDING                              /   CULVERTS                                                   E AND MAIN HIGHWAY.
LABORATORY

PLACING   CONCRETE    ON                                  CONCRETE REPAIR                                            CONSTRUCTION                             OF           PIPE
SERVICE                                                                                                              RACK BASES
WATER    TANK   58-TK-205                                 Top
FOUNDATIONS

EXCAVATION      IN  Operating                             CONSTRUCTION   OF  MAIN                                    REMOVAL                    OF            HAZARDOUS
Authority CONTROLLED AREAS                                SUBSTATION                                                 MATERIALS
CONSTRUCTION OF FLOOR SLAB                                MORTAR FOR BLOCKWORK                                       CONTROL OF CAMP SEWAGE SYSTEM
CENTRAL CONTROL BUILDING
STRUCTURAL STEEL-PIPERACKS                                COMPRESSORS‟ STRUCTURES                                    EXCAVATION FOR
                                                          RCC COLUMN PLATE INSERTS                                   132KV CABLE INTERCONNECTION
ROAD CROSSING                       FOR          132      NIGHT   SHIFT                   WORKING               -    GROUTING TO PIPE RACK FOUNDATION
KV ROUTE                                                  EARTHWORKS                                                 BASES
CEMENTITIOUS   GROUTING                           TO      ETYLENE COMPRESSOR                                         PROPANE COMPRESSOR
FOUNDATION BASES                                          MASSIVE FOUNDATION (CONCRETE                               MASSIVE FOUNDATION (CONCRETE POUR)
                                                          POUR
PROPANE COMPRESSOR                                        PROPANE COMPRESSOR                                         PROPANE COMPRESSOR
MASSIVE FOUNDATION (CONCRETE                              MASSIVE FOUNDATION (CONCRETE                               MASSIVE FOUNDATION (CONCRETE POUR
POUR)                                                     POUR
PROPANE COMPRESSOR                                        SEAWATER BASIN                                             SEAWATER BASIN
MASSIVE FOUNDATION (CONCRETE                              (WATER TIGHTNESS BS 8007 : 1987 )                          (WATER TIGHTNESS BS 8007 : 1987 )
POUR
SEAWATER BASIN                                            ADMINISTRATION BUILDING                                    ADMINISTRATION BUILDING
(WATER TIGHTNESS BS 8007 : 1987 )                         STAIR LANDING EXTENSION AT GRID 4                          STAIR LANDING EXTENSION AT GRID 4 J
                                                          J
ADMINISTRATION BUILDING                                                                                              ADMINISTRATION BUILDING
STAIR LANDING EXTENSION AT GRID 4                         FENCING                                                    CERAPlant  Operating   Authority                        TILES
J                                                                                                                    FLOORING SYSTEM
                                                          Top
ADMINISTRATION BUILDING                                   ADMINISTRATION BUILDING                                    ADMINISTRATION BUILDING
CERAPlant Operating Authority TILES                       PLASTERING AND RENDERING                                   ROOFING SYSTEM
FLOORING SYSTEM
ROOFING SYSTEM                                            BUILDINGS                                                  CRACKED GAS COMPRESSOR TABLE TOP
                                                          ROOFING SYSTEM                                             CONCRETE POUR

WATER TIGHTNESS TESTS FOR THE                             WATER TIGHTNESS TESTS FOR THE                              ADMINISTRATION BUILDING
COLLECTION SUMPS ACCORDING TO                             COLLECTION SUMPS ACCORDING TO                              MARBLE FLOORING
BS 8007 : 1987 SECTION 9                                  BS 8007 : 1987 SECTION 9

ETHYLENE GAS COMPRESSOR                                   PROPANE GAS COMPRESSOR                                     EXPANSION JOINTS IN DITCHES
TABLE TOP POUR                                             TABLE TOP POUR

EXPANSION JOINTS IN DITCHES                               CONCRETE COATING                                           DEWATERING FOR THE 84” GRE                               PAIR
                                                          USING MASTER SEAL 550                                      LINE PARALLEL TO
Top                                                                                                                  CORNICHE ROAD    EAST WEST


CERAPlant Operating Authority WALL                        BEDDING AND GRAVEL FILLING                                 EXTERNAL              CONCRETE               PROTECTION
                                                          BENEATH 60 “ DIA PIPE COOLING
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              3 of



TILES FIXING                                              WATER PIPE                                                 ADMINISTRATION BUILDING

ABOVE     GROUND       CONCRETE                           ABOVE     GROUND       CONCRETE                            HAND EXCAVATION TO INSTALL
PROTECTION                                                PROTECTION                                                 TELEPHONE DUCTS BETWEEN BOX NO. 20
USING MASTERSEAL 300 H                                    USING MASTERSEAL 300 H                                     TO TELECOM CENTRE

BACKFILLING OF THE WEST SIDE OF                           EXCAVATION -                                               DRILLING OF HOLES ON
THE QUENCH TOWER FOUNDATION –                             COOLING WATER OUTFALL CHAMBER                              PIPE RACK & STRUCTURES ON SITE
(RIB)
SITE OFFICE ESTABLISHMENT                                 Welding of Earthing Lugs on                                FILLING AROUND ALL THE PIPES WITHIN THE
                                                          East West Piperack (SR0099A &B)                            Plant AREA

PRECASTING MAN HOLES                                      TERMINATION        DETAIL    TO                            TERMINATION DETAIL TO PROTECTIVE
CATCH BASIN AND                                           PROTECTIVE MEMBRANE AROUND                                 MEMBRANE      AROUND    RCC  COLUMNS
VALVE CHAMBERS                                            RCC COLUMNS SUPPORTING THE                                 SUPPORTING THE STRUCTURAL STEEL
                                                          STRUCTURAL STEEL                                           COLUMNS FOR PIPE RACKS
                                                          COLUMNS FOR PIPE RACKS                                     CASE (1) WITH ALUMINIUM BEAD
                                                          CASE (1) WITH ALUMINIUM BEAD                               CASE (2) WITH REBATE
                                                          CASE (2) WITH REBATE                                       CASE (3) GRAVEL FILL
                                                          CASE (3) GRAVEL FILL                                       CASE (4) PAVING
                                                          CASE (4) PAVING

                                                          ROAD CROSSING FOR LAYING 2 PIPES
Top                                                       1 FOR 20” RAW ETHANE & 1 FOR 6”
                                                                                                                     ROAD CROSSING FOR LAYING 2 PIPES
                                                                                                                     1 FOR 20” RAW ETHANE
                                                          PROPANE                                                    &
                                                          FIRST STREET Operating Authority                           1 FOR 6” PROPANE
                                                          ENTRY
                                                                                                                     FIRST STREET Operating Authority ENTRY
DIRECTIONAL BORING                                        2 #s ROAD CROSSINGS                                        2 #s ROAD CROSSINGS
FOR LAYING SLEEVES FOR                                    FOR LAYING                                                 FOR LAYING
2 PIPES                                                   1 FOR 14” DESALINATED WATER                                1 FOR 14” DESALINATED WATER
1 # 20” RAW ETHANE                                        1 FOR 8”POTABLE WATER                                      1 FOR 8”POTABLE WATER
&                                                         &                                                          &
1 # 6” PROPANE                                            1 FOR 20” RAW ETHANE                                       1 FOR 20” RAW ETHANE
Operating Authority Plant REFINERY                        1 FOR 8” NATURAL GAS                                       1 FOR 8” NATURAL GAS
ENTRY                                                     1 FOR 6” PROPANE                                           1 FOR 6” PROPANE
                                                          AVENUE „C‟                                                 AVENUE „C‟
                                                          AT FIRE STATION                                            AT FIRE STATION

ADMINISTRATION BUILDING                                   PAINTING ADMINISTRATION BUILDING                           PAINTING ADMINISTRATION BUILDING
GRC
PANEL FIXING                                                                                                         Top
ROAD CROSSING FOR LAYING 2 PIPES                          EARTHWORKS                             SURVEY              ROAD CROSSING FOR LAYING
1 FOR 20” RAW ETHANE                                                                                                 84”G R E PAIR SEAWATER
&                                                         SYSTEM                                                     COOLING LINES
1 FOR 6”PROPANE                                                                                                      AT
AVENUE „C‟                                                                                                           AVENUE „D‟ / CORNICHE
                                                                                                                     JUNCTION

ROAD CROSSING FOR LAYING                                  TENNIS COURTS SURFACING                                    PRECASTING  LIGHTING                                POLES
84”G R E PAIR SEAWATER
COOLING LINES
                                                                                                                     FOUNDATIONS
AT
AVENUE „D‟ / CORNICHE
                                                          Top
JUNCTION

LIGHTING                                  POLES           SEA WATER SURGE BASIN                                      CONCRETE COATING OF                         STRUCTURES
FOUNDATIONS                                               CONCRETE PROTECTION                                        USING MASTERSEAL 550
                                                          MASTER SEAL 550

ABOVE             GROUND              CONCRETE            SEA WATER SURGE BASIN JOINT                                PAINTING
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              4 of



PROTECTION                                                SEAL                                                       SUB STATIONS
SEAWATER SURGE BASIN

PAINTING                                                  ELECTRICAL            &    INSTRUMENTATION                 ELECTRICAL                &         INSTRUMENTATION
SUB STATIONS                                              TRENCHES                                                   TRENCHES

PULL PITS                                                 PULL PITS                                                  PULL PITS
ROAD CROSSING TO MAKE GOOD                                ROAD CROSSING TO MAKE GOOD                                 ROAD CROSSING
WEARING COURSE OVER COMPLETED                             WEARING COURSE OVER COMPLETED                              TO MAKE GOOD (temporarily)
1# FOR 14” DESALINATED WATER                              132 KV ELECTRIC CABLE                                      WEARING COURSE OVER COMPLETED
&                                                         AVENUE „C‟                                                 132 KV ELECTRIC CABLE
1# FOR 8”POTABLE WATER                                                                                               AVENUE „C‟
AVENUE „C‟

DRINKING                                 WATER            PROTECTION    TO    TRANSFORMER                            TIMBER DOORS FIXING
                                                          FOUNDATION SIDES IN SUB STATIONS                           ADMINISTRATION BUILDING
CONNECTION                                                WITH       ALUMINIUM        BEAD
                                                          TERMINATION FOR BELOW GROUND
                                                          AND MASTERSEAL 300H FOR ABOVE
Top                                                       GROUND IN GRAVEL FILL AREA

GROUTING    TO    STEEL                      TANKS        GROUTING    TO    STEEL                      TANKS         EXCAVATION            FOR       CCB      UNDERGROUND
BEARINGS ON RING BEAMS                                    BEARINGS ON RING BEAMS                                     WATER TANK

EXCAVATION     FOR                              CCB       SOAKAWAY CHAMBERS                                          EPOXY FLOORING
UNDERGROUND WATER TANK
                                                                                                                     BUILDINGS

EPOXY FLOORING                                            EPOXY FLOORING                                             VINYL WALL COVERING
BUILDINGS                                                 BUILDINGS                                                  BUILDINGS

DRY WALL LININGS                                           RUBBER FLOORING                                            RUBBER FLOORING
BUILDINGS                                                  (BUILDINGS)                                                (BUILDINGS)

RUBBER FLOORING                                            RUBBER FLOORING                                            RUBBER FLOORING
(BUILDINGS)                                                (BUILDINGS)                                                (BUILDINGS)

SUSPENDED CEILINGS                                        PIT 21 WATER CONNECTION                                    CEMENT BASED NON SHRINK GROUTING TO
ALL BUILDINGS                                                                                                        FOUNDATION BASES
                                                                                                                     USING MASTERFLOW 928 T
                                                          Top
REPAIR  OF              CONCRETE            FLOOR         REPAIR  OF                CONCRETE           FLOOR         EPOXY GROUTING TO
SCREEDS                                                   SCREEDS                                                    VIBRATING INSTALLATION BASES
                                                                                                                     USING MASTERFLOW 648 CP
                                                                                                                     GENERAL FOUNDATIONS
Top
KERBS &   INTERLOCKING BLOCKS                             ERECTION OF STEEL STRUCTURES                               VINYL FLOORING
PAVING AROUND BUILDINGS                                   (FOR HIGHER LEVELS)                                        BUILDINGS

CONCRETE PAVING                                           CENTRAL CONTROL BUILDING                                   CONCRETE PLACEMENT
                                                          CERAPlant Operating Authority TILES
                                                          FLOORING SYSTEM
PRECAST RCC COVERS                                        BLACK TOP REPAIR                                           REPAIR OF
CABLE    &     INSTRUMENTATION                            IST STREET BETWEEN                                         SINGLE LEAF SWING GATES
TRENCHES                                                  AVENUE C & B

REPAIR TO                                                 RESIN INJECTION TO LEAKING JOINT                           RESIN INJECTION TO LEAKING JOINT
FLOOR SCREED LEVELS                                       SEA WATER SURGE BASIN                                      SEA WATER SURGE BASIN

Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              5 of



RESIN INJECTION TO LEAKING JOINT                          FIRE WATER LINE EXCAVATION                                 ROAD CROSSING
SEA WATER SURGE BASIN                                     AROUND   CONSUMER  RECEIPT                                 FOR LAYING
                                                          STATION                                                    1 FOR 20” RAW ETHANE
                                                                                                                     1 FOR 6” PROPANE
                                                                                                                     FIRST STREET

ROAD CROSSING                                             2 #s ROAD CROSSINGS                                        TREATMENT TO MOVED EXPANSION JOINTS
FOR LAYING                                                FOR LAYING                                                 SEA WATER SURGE BASIN
1 FOR 20” RAW ETHANE                                      1 FOR 20” RAW ETHANE
1 FOR 6” PROPANE                                          1 FOR 8” NATURAL GAS
FIRST STREET                                              1 FOR 6” PROPANE                                           Top
                                                          &
                                                          1 FOR 14”DESALINATED WATER
                                                          1FOR 8” POTABLE WATER
                                                          AVENUE -D

TESTING OF FRESH CONCRETE ON                              ROAD CROSSING                                              ROAD CROSSING
SITE                                                      TO INSTALL CULVERT FOR                                     TO INSTALL CULVERT
                                                          1# 14” DESALINATED WATER                                   FOR
                                                          CORNICHE ROAD / ROAD C                                     1 # 14” DESALINATED WATER
Top                                                       AT GUP GATE NOTH                                           AVENUE „C‟ ROAD GUP GATE EAST
                                                                                                                     MAIN ENTRANCE

ROAD CROSSING                                             ROAD CROSSING                                              REPLACEMENT OF MISALIGNED ANCHOR
TO INSTALL CULVERT                                        TO INSTALL CULVERT                                         BOLTS
FOR                                                       FOR                                                        IN
1 # 14” DESALINATED WATER                                 1 # 14” DESALINATED WATER                                  FOUNDATION 55-VV-906
AVENUE „C‟ ROAD GUP GATE EAST                             AVENUE „C‟ ROAD GUP GATE EAST                              USING RENDEROC LAX TRA
MAIN ENTRANCE                                             MAIN ENTRANCE

REPLACEMENT      OF MISALIGNED                            BUILDINGS                                                  BUILDINGS
ANCHOR BOLTS                                              SCREEDS FOR VINYL AND EPOXY                                SCREEDS FOR VINYL AND EPOXY
IN                                                        FLOOR FINISHES                                             FLOOR FINISHES
FOUNDATION 55-VV-906
USING RENDEROC LAX TRA

BUILDINGS                                                 DIRECTIONAL    BORING       AT 3#                          DIRECTIONAL BORING AT 3# LOCATIONS
SCREEDS FOR VINYL AND EPOXY                               LOCATIONS FOR 14”DESALINATED                               FOR    14”DESALINATED      WATER PIPE
FLOOR FINISHES                                            WATER PIPE CORNICHE ROAD                                   CORNICHE ROAD
                                                          NORTH OF Operating Authority                               NORTH OF Operating Authority
DIRECTIONAL    BORING   AT 3#                             DIRECTIONAL    BORING   AT 3#                              EPOXY SKIRTING IN
LOCATIONS FOR 14”DESALINATED                              LOCATIONS FOR 14”DESALINATED                               CENTRAL CONTROL BUILDING
WATER PIPE CORNICHE ROAD                                  WATER PIPE CORNICHE ROAD                                   & SUB STATIONS ON DRY LINING
NORTH OF GUP                                              NORTH OF GUP
EPOXY SKIRTING                                            EPOXY SKIRTING                                             ROAD SURFACE
ON DRY LINING                                             ON DRY LINING                                              REINSTATEMENT
                                                                                                                     OVER BOX CULVERT CROSSINGS
                                                          REPAIR TO LIFT                                             FIXING SHEETING PANELS
Top                                                       CLADDING PANEL                                             WALL & ROOF CLADDING
                                                          ADMINISTRATION BUILDING
FIXING SHEETING PANELS                                    ROAD CROSSING                                              SEA WATER SURGE BASIN
WALL & ROOF CLADDING                                      AT FIRE STATION- FIRST STREET                              CLOSING THE STRUCTURAL GAP
                                                          FOR LAYING                                                 ON THE ROOF, WALL & BASE SLAB
                                                          2 # 100 mm SLEEVES
                                                          FOR TELEPHONE CABLES
HDPE PIPES                                                ROAD CROSSINGS                                             ROAD CROSSINGS
BUTT FUSION                                               TO CONSTRUCT BOX CULVERTS OFH                              TO INSTALL CULVERTS OFH 4 & 5
                                                          2&3                                                        CORNICHE ROAD ETHYLENE EXPORT
                                                          CORNICHE ROAD
                                                          ETHYLENE EXPORT

MDPE DRINKING WATER LINE – NY                             ROOF & SIDE CLADDING – Plant AREA                          FOUNDATIONS ALONG FENCE BELOW
LINES
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              6 of



                                                                                                                     „FERTIL OVER HEAD CONVEYOR‟
                                                                                                                     FOR PIPE RACK LEADING TO SEA
REINSTATEMENT TO                                          REINSTATEMENT TO                                           Maintenance Warehouse
„DAMAGE CAUSED                                            „DAMAGE CAUSED                                             Overcoating
FLARE PIPE RACK                                           FLARE PIPE RACK                                            To Epoxy Painted Surface
COLUMN MEMBER 01537‟                                      COLUMN MEMBER 01537‟                                       With
 AT GRID 19A                                               AT GRID 19A                                               Mastertop Top Coat 44P
                                                                                                                      Access to Corridors & Walkway

Roads                                                     Roads                                                      Excavation for 200 pair Telecom Route
Bituminous Concrete Surfacing                             Bituminous Concrete Surfacing                              (Direct Buried)
                                                                                                                      parallel to Avenue D & 3rd street

Hand Excavation for 200 pair Telecom                      200 pair Telecom Road Crossing                             Manual Excavation
Route                                                     at Avenue D / 3rd Street Intersection                      200 pair Telecom Road Crossing
(Direct Buried)                                           along E 676976                                              @ Access road to GASCO camp
parallel to Avenue C                                                                                                 @ C / L, co-ordinate N 2666305 / avenue C

Manual Excavation                                         REMOVAL OF CONTAMINATED                                    BLINDING CONCRETE
200 pair Telecom Road Crossing
 @ Access road to Operating Authority
                                                          SOIL
camp
@ C / L, co-ordinate N 2666940 /
avenue C
REINFORCEMENT         RECEIVAL     &                      REINFORCEMENT PLACEMENT                                    FORMWORK ERECTION
FABRICATION

CONCRETE TO PAVED AREAS                                   EXCAVATION              &      BACKFILL            TO      TELEPHONE CABLE TO SITE OFFICE
                                                          STRUCTURES

ELECTRIC  CABLE  FROM    RLIP                             WATER SUPPLY TO Civil Contractor                           ADMINISTRATION BUILDING SUBSTRUCTURE
SUBSTATION TO Civil Contractor                            CAMP
CAMP

WASTE MANAGEMENT                                          SEA WATER BASIN                                            EXCAVATION FOR
                                                                                                                     ETHANE & PROPANE
                                                                                                                     GAS PIPELINE INTERCONNECTION

                                                          Top
GENERAL

#1

Site Preparation & Earth Work
Top
Index
Scope - Reference documents – Definitions – Responsibilities – Safety – Method – Equipment
- Attachment
Scope
The purpose of this method statement is to define the sequence of activities for the site
preparation works related to the Company Petrochemical project. The extent of these activities
are defined upon the attached site plan (Not included with this statement). Refer to indicative
google photos.
Reference documents
Specifications for:
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              7 of



Site preparation,Excavation & backfill for underground installations,Fill, Grading and
Paving,Testing Laboratory,Geotechnical Investigation
Definitions
GE                        Geotechnical Engineer
PSM                       Project Site Manager
SE                        Site Engineer
SO                        Safety Officer
QM/QE                     Quaity Manager/Quality Engineer
IS                        Infrastructure Superintendent
ST                        Survey Team
PPE                       Personal Protective Equipment
Responsibilities
It is an overall responsibility of the PSM to ensure that the site preparation activities are
conducted according to the project specifications. PSM shall arrange all required resources.
The IS shall ensure that the site preparation activities are conducted according to this method
statement as well complying with all specifications.
The GE shall ensure that the activities are conducted according to the project specifications
and this method statement.
Safety
Prior to the commencement of any activities, the workforce shall receive a toolbox talk on the
project site as well as on general safety requirements. SO shall ensure that the persons being
inducted on site are well aware of the safety procedure to be implemented on site for the
activity concerned.All persons upon the site shall wear PPE issued to them. Where possible
hazards may arise from excavation activities, the necessary safety measures shall be taken to
prevent accident or injury at all times. This may include provision of signage, barriers,
watchman and lighting.Where work upon existing services is required, the necessary authority,
permits and safety equipment shall be attained prior to the activity commencing. Scanning of
existing services shall be conducted by suitable methods.
Method
The survey team shall locate and mark all services that are present upon the site (This
includes above ground services as well as buried services). These services, (Electric,
telephone, gas, oil, chemical, water etc), shall be clearly marked using stakes and warning
tapes, reflected upon a site drawing and the issues raised with the client.
The survey team shall also mark upon the site plan all obstructions, structures and
developments. Any obstruction encountered during excavation activities shall be plotted and
recorded.

Where hazardous material is encountered, it shall be identified and isolatedin compliance with
the safety procedures under SO supervision. The client shall be informed & hazardous
material be collected and removed to a licensed tipping place. The details of the material and
tipping arrangements shall be documented for review by the client as appropriate. Refer to
Method statement Removal of hazardous materials.

Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              8 of



Existing structures, fences and developments shall be demolished in a safe manner as site-
stripping activities proceed. The necessary permits, approvals and permission shall be
obtained from the concerned authorities prior to the commencement of the activity. The
method of removal of these existing elements shall usually be conducted by dozer or breaker.
Where necessary otherwise, discussions on site shall be made concerning alternate methods
of removal when the full extent of these structures are exposed.

The removal of the topsoil shall include all vegetation and rubbish material from the work site.
Prior to the start of topsoil removal, the surveyor shall peg out the haul roads to be used by the
construction equipment to execute all the site preparation activities. These roads shall be
constructed by leveling of the existing terrain. Grade pegs shall be set to an agreed grid to
indicate existing grade and reduced grade. Dependant upon the quality of the existing soil
where the roads is to be built, suitable compactable fill may be imported or re-located from
other parts of the site. The material shall be approved by the GE & QM/QE jointly.

These roads shall be maintained as the work proceeds.
Where required, water shall be spayed for dust control.

For general removal of the topsoil activities using appropriate equipment, the areas concerned
shall be excavated and graded to levels that ensure adequate surface water drainage. The
GE/QM/QE shall monitor the activity to ensure that the topsoil material is removed. Sampling
and testing of the resultant material shall be conducted for specification compliance & proper
compaction.

Upon completion of the topsoil removal activities where appropriate, the exposed surface shall
be scarified, moistened and compacted to achieve the required density criteria. The areas shall
be divided into manageable sections that be defined upon sketches. The GE shall monitor and
test all sections. The results of the tests shall be recorded upon the relevant QC format. The
number of tests conducted shall reflect the specification requirement.

In excavation areas, the GE shall review the material to be excavated to ascertain its suitability
for re-use as fill material. This excavated material shall be transported to areas that require
filling. The material shall be deposited onto the areas to receive filling, leveled, moisture
conditioned and compacted. If necessary, stockpiling may be required.

The excavated areas shall be divided into manageable sections, which be defined upon
sketches. The excavated areas shall be monitored by the GE to ensure that any unsuitable
material does not appear. Where unsuitable material appears, it shall be removed. The
excavated formation surface shall be treated by scarification, moistened and compacted
according to the specification criteria. All areas shall be tested and the results recorded.

Where areas are to receive fill, the material that has been excavated shall be transported to
the fill area, tipped, leveled, moisture conditioned and compacted. The material shall be spread
and leveled in 200mm layers. The areas to be filled shall be divided into manageable sections
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              9 of



that be defined upon a sketch. The fill layer shall be moistened and compacted to achieve the
required specification criteria. No further fill activity shall be conducted upon an area that has
not been approved and released by the GE. Attention shall be observed at edges and slopes,
to ensure that compaction criteria are achieved. Additional layers of fill material shall be placed
similarly as described above until the desired elevation has been achieved.

Production procedure.
Verification exercise for fill activity had been conducted to establish the economical and
effective method for the fill activity.
Import and place fill to controlled areas of approximately 25m wide by 100 - 150m long.
Spread and level the imported fill.
Add water to the fill layer by passing the water tanker over the fill layer. The water tanker
should pass over the layer twice.
A time gap of approximately two hours is allowed for the water to soak into the fill material.
The layer is now mixed with the grader until a uniform blend of moist material is achieved.
Additional water is added by passing the water tanker over the layer in a uniform sequence. A
time period of approximately one-hour is allowed for this water to soak into the fill layer.
The fill layer is mixed again with the grader leaving the fill level to the correct grade.
Vibrating rollers shall now compact the fill layer in a logical sequence that compacts the fill
layer uniformly.
Testing of the layer shall be conducted according to specification requirements.

Equipment
Dozers & Graders, Vibrating drum rollers, Dumper trucks, Excavators & Loaders, Water
tankers

Attachment
None. Refer to indicative google photos as incuded as a facility. Assume there was nothing
prior to construction & whole site was filled for preparationworks.

#2

Protection of existing services
Top

Index
Scope - Reference documents – Definitions – Responsibilities – Safety – Method – Equipment -
Attachment
Scope
The purpose of this method statement is to define the procedure that can be implemented, for
the identification, protection and / or removal / relocation of existing services upon the site.
Reference documents
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              10 of



Specifications: Site preparation…, Fill…, Grading and Paving...(certain sections re to record
services within the specifications)
Definitions
GE                        Geotechnical Engineer
PSM                       Project Site Manager
SE                        Site Engineer
SO                        Safety Officer
QM/QE                     Quaity Manager/Quality Engineer
IS                        Infrastructure Superintendent
ST                        Survey Team
PPE                       Personal Protective Equipment
Responsibilities
It is the overall responsibility of the PSM to ensure that the identification, protection and / or
removal / rerouting to existing services are conducted in a safe methodical sequence as
defined by this method statement as well as directed by the relevant authorities.
The IS shall coordinate investigation of existing services with the Plant authorities.
The ST shall accurately plot and record all existing services upon the site.
The SE shall ensure that the excavation is rightly carried out.
The SO shall ensure that excavations are safely carried out.
Safety
Prior to the commencement of any activities, the workforce shall receive a safety induction talk
on the project site safety requirements.
The necessary permits that may be required to work near these services shall be obtained.
Any special conditions imposed upon these permits shall be implemented.
The use or restriction of specific mechanical equipment whilst locating these services shall be
implemented. Generally, where appropriate, only manual excavation shall be carried out.
Method
From the existing record drawings provided by the relevant authorities controlling Plant,
existing services shall be located and exposed by hand excavation.
The ST shall check and accurately record these services. A line of pegs shall be positioned to
indicate the route of the existing services. The warning tape and / or nylon cord to indicate
and protect the route of the service shall be provided. The ST shall inform the IS about the
exact location of the services relative to the warning flags.

Should an existing service be disbanded or made redundant, that shall be exposed to allow for
the inspection as well as confirmation of its status by the authorities. The IS through the EPC
Contractor representative shall request the relevant authority to review the excavated service
to confirm the status as well as instruct for necessary action required for removal or diversion.
The redundant service shall be removed under the supervision of the IS according to the
agreed criteria of that relevant authority.




Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              11 of



Where an existing live service remains working or serving during the site preparation activity
such as the 33KVA electric cable, that existing live service shall be protected in compliance
with the regulations.

Upon location of the live service, the ST shall mark that location upon the ground using spray
paint or small pegs. At necessary locations along the route of the existing live service indicated
by the ST, small hand dug pits shall be excavated to expose live service to ensure its location.
On ten meters (10m) either side of the route of the existing live service shall be erected posts
at suitable centres. A nylon cord with warning tape streamers shall be strung between the
posts to clearly indicate the service and its route.

Signboards that indicate what exactly the live service within the marked corridor is, shall also
be displayed at sufficient locations conveniently within the view along the route.

Where temporary roads cross existing cables, sufficient suitable fill material shall be placed on
top of the cables to afford adequate protection by distributing the axle loadings safely.

The Safety Officer shall periodically check the condition of the barriers where necessary
refurbishment is conducted.

Equipment
Excavation Tools, Survey Equipment, Pegs, Nylon cord, Warning tape.
Attachment
None. Attachments depends on the available record drawings.
#3

Re-routing of 33kv cables
Top
Index
Scope- Reference documents- Definitions- Responsibilities- Safety- Method- Equipment-
Attachment
Scope
The purpose of this method statement is to define the procedure that can be implemented for
re-routing of the existing 33KV electric cable that crosses the project site. This method
statement includes the location, excavation, isolation, re-routing, jointing, testing and backfill.
Reference documents
Site drawing, Record Drawings
Definitions
GE                        Geotechnical Engineer
PSM                       Project Site Manager
SE                        Site Engineer
SO                        Safety Officer
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              12 of



QM/QE                     Quaity Manager/Quality Engineer
IS                        Infrastructure Superintendent
ST                        Survey Team
PPE                       Personal Protective Equipment
Responsibilities
The EPC Contractor PSM shall ensure the required permits from Operating Authority are
obtained prior to the commencement of this activity.
It is the overall responsibility of the PSM to ensure that the identification, protection and / or
removal / rerouting to existing services are conducted in a safe methodical sequence as
defined by this method statement as well as directed by the relevant authorities.
The IS shall coordinate investigation of existing services with the Plant authorities.
The ST shall accurately plot and record all existing services upon the site.
The SE shall ensure that the excavation is rightly carried out.
The SO shall ensure that excavations are safely carried out & ensure that all safety issues are
addressed as defined upon the work permits.
Safety
Prior to the commencement of any activities, the workforce shall receive a safety induction talk
on the project site safety requirements.
The necessary permits that may be required to work near these services shall be obtained.
Any special conditions imposed upon these permits shall be implemented.
Only specifically approved mechanical equipment whilst locating these services shall be used.
Generally, where appropriate, only manual excavation shall be carried out.
Method
The existing route of the 33KV cable shall be identified, marked & a barrier erected on either
side clearly defining the route across the site.

The route proposed for the new 33KV cable on the AFC drawing shall be identified & marked
with pegs by the ST. Excavation shall commence to the line and required level.

The appropriate sand bed shall be placed within the trench.

The new cable supplied by EPC Contractor shall be laid into the trench according to
established methods and standards that would include placing of the cable drum on a cable
trolley and rollers. The cable shall be unwound from the cable drum by pulling. If required, a
cable tugger fitted with load cell control may be utilized.

The new cable shall be correctly placed to line and level upon the sand bed. Wherever joints
occur, sufficient cable overlap to allow for the jointing shall be provided.

The insulation value of the new cable shall be tested by 5KV motorized megger.




Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              13 of



Upon the EPC Contractor Electrical Engineers approval, the cable shall be covered with dune
sand to the required thickness evenly. Cable tiles shall be placed on top of the sand above the
new cable.

The trench shall be backfilled with approved material. The backfill activity shall continue until
the trench is completely filled. Route markers shall be placed with the splice joints surveyed
and recorded.

Where joints occur to the cable either at the two termination points with the old cable or along
the length of the new cable, the same technique shall be adopted.

An experienced cable jointer under the supervision of an electrical engineer shall conduct all
the jointing.

Approved jointing kits shall be utilized. The manufacturers recommendations relating to the
installation of these jointing kits shall be followed.

Upon completion of the jointing of the new cable length, the entire length of the new cable shall
be tested. The cable shall be subjected to a pressure test of 67KV DC for 15 minutes on the
cable between each core and earth. The remaining cores shall be connected to earth. The
engineer shall measure the leakage current. All readings shall be recorded upon the
appropriate form. The testing shall be witnessed by the EPC Contractor engineer.

Prior to the excavation at the points where the new cable is to be connected to existing 33KV
cable, the necessary permits shall be obtained. EPC Contractor method statement for
conducting cable Diversion shall be complied with.

The old cable shall be hand dug. An area sufficient to conduct the jointing of the cable shall be
excavated.

Electrical engineer in coordination with the EPC Contractor engineer shall ensure that the old
cables are identified and isolated under the supervision of the Refinery Supervisor within the
appropriate substation. The necessary earthing and isolation to the cables shall be conducted
prior to the commencement of jointing the old cable to the new.
The cables shall be jointed in the same manner as described previously.

Once the cables have been jointed, these shall be tested by mega test at 5KV and HV test at
53KVDC to establish its integrity and insulation.

The disbanded cable shall be removed from the new jointed cable by excavating and rolling
the cable to allow the new cable route corridor to be covered with sand, cable tiles and backfill
material.


Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              14 of



Upon completion of the cable testing activities, the Refinery Electrical engineer shall authorize
the energizing of the new cable route.

The disbanded cable route shall be excavated to expose the old cable. The old cable shall be
removed onto the surplus cable drums from which the new cable was coiled. These drums
shall be stored on site for EPC Contractor disposal.

A program to be developed by all parties of power outage windows shall be produced for the
tie-in activities of the cables.

Equipment
Excavator,Dump trucks,Cable drum trolley,Cable rollers,Cable tugger with load cell
Attachment
EPC Contractor standard method statement for cable diversion.
(Since this statement may be submitted by the Civil Works subcontractor on behalf of the EPC
contractor, the EPC standard method statement is required to be attached)
Top

Concrete Pipe Culverts
Index
Scope-Reference documents-Definitions-Responsibilities-Safety-Method-Equipment-Attachment
Scope
The purpose of this Statement is to define the sequence and methodology for the laying,
jointing and testing of the concrete pipe culverts.
Reference documents
Specification….,Drawing No….
Definitions
GE                        Geotechnical Engineer
PSM                       Project Site Manager
SE                        Site Engineer
SO                        Safety Officer
QM/QE                     Quaity Manager/Quality Engineer
IS                        Infrastructure Superintendent
ST                        Survey Team
PPE                       Personal Protective Equipment
Responsibilities
The CS shall Plan and Resource the concrete culvert laying activities to ensure that these are
Carried out complying with the contract documents.
The Construction Foreman shall actually execute the works controlling the workforce as
necessary all according to the directions by the site engineer or the superintendant.

Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              15 of




Safety
Prior to the commencement of any activities, the labour force shall receive a toolbox talk on the
Project Site Safety requirements. Any adopted process that may have a particular Safety risk,
shall be assessed, shortcomings analysed and addressed accordingly meeting the operational
requirement.
Method
Setting Out
The edge co-ordinates of the concrete pipe shall be calculated from the information on IFC
drawing. Allowing for the 1:1.5 slope, the edges shall be fixed in such a way that full length of
pipes are used avoiding unnecessary cutting. The center line and the actual trench width shall
be set out by marking on ground.
Excavation
The trench shall be excavated to the correct width, length and formation by using a Hydraulic
backhoe. Once the bulk excavation is completed, wooden pegs with elevation marked on them
shall be used for indication to complete the remaining excavation to accurate formation levels.
The formation shall be watered and compacted with a plate compactor to achieve compaction
of 90% of MDD in accordance with specification documents. The compacted formation shall be
inspected and field tested prior to the commencement of the Bedding activity.
Bedding
Once the excavation is approved, Bedding material shall be placed to a thickness of 150mm,
watered and compacted in accordance with the specification. The compacted surface shall be
inspected & field samples tested for approval.
Pipe Work
The socket positions shall be marked on the Bedding and Hand excavated to ensure that the
barrel of the pipe rests firmly on the bedding with spigot ends remaining clean for installing the
gaskets.
The concrete pipes shall be transported from the store to the location of the trench and gently
lowered keeping the socket end upstream into the trenches with a crane using belt slings only.
The pipes shall be laid back to back to the correct orientation. The spigot end of the pipes shall
be cleaned using a cloth with special care taken to clean the recess which shall be lubricated
with liquid soap following gasket placement in position.
Supports shall be placed at one end. The spigot shall be so placed that the gasket is in contact
with the entry taper at the socket evenly all around.
The spigot shall then be drawn into the socket using a 5 tonTirfor. Jointing shall be carried out.
Upon completion of the Jointing operation, the Bedding material shall be packed below the
pipes so that the barrel rests firmly on the bedding keeping the pipe intact. The top elevation of
the pipe shall be checked to ensure that the pipe lebvel is accurate. The operation shall be
repeated until all the pipes are laid. The completed pipework shall be inspected and approved.
Each joint shall be visually inspected from inside the pipe.
Backfill
Once the pipes are laid to the True gradient and alignment as described above, Bedding
Material shall be carefully placed along the sides and in between the pipes by means of a
backhoe. The bedding and surround material shall be placed in layers and watered and
compacted until the bedding and surround material reaches 300mm above the top of the pipe.
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              16 of



Excavated suitable material shall then be placed in 200mm layer, compacted, inspected and
tested.
A list of Do‟s and Don‟t‟s provided by the manufacturer is attached herewith.
Equipment
Crane 20Ton 1 No / Flat Bed TrailorPart time / Excavator Backhoe1 No / Trifor 5 To 2Nos
/ Fork liftParttime / Plate Compactor1 No / Water Tanker Part time
Labour
ForemanNo. 1 / PipefitterNos. 2 / LabourersNos. 4
Attachment
Manufacture‟s datasheet.
Top
#5

Concreting to walls of
Central control building / laboratory
Super – structure activities
Top
Index
Scope / Reference documents / Definitions / Formwork Design / Method
Scope
The purpose of this method statement is to define the procedure that shall be adopted for the
erection of formwork and placement of structural concrete to the wall sections of the CCB.
Reference documents
Specification Concrete Construction, Formwork and Coating.
Specification Concrete Buildings.
Drawing No.
Definitions
E                        Engineer
PSM                      Project Site Manager.
CM                       Construction Manager.
Formwork system
The basic formwork supporting system shall be as designed and supplied by M / s. Giffin
Scaffco. The supplier of formwork shall provide all design drawings for approval as well as for
implementation. Additional bracing and support props shall be added by Civil Contractor in
compliance with the formwork design provided by the supplier. Surface forming materials such as plies
& timber scantlings etc. shall be added by the civil contractor. Upon completion of the suspended slab
formwork system particularly, Civil Contractor Site Engineer shall check and confirm the adequacy of

Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              17 of



the system. If so required, the whole form work shall then be checked by the supplier‟s expert & the
adequacy certified in as by third party.
Method
The surveyor shall set out, check the line and levels to establish the correct positions. The wall
starter bars shall be installed in place in accordance with the IFC drawings for the foundations.
The kicker to the base of the wall sections shall be planned to be cast along with the
foundation.
The vertical and horizontal reinforcement to the wall shall be installed according to the IFC
drawings. Where service inserts (ducts pipes etc) are shown on IFC drawings, these shall be
securely located,installed as well as checked.
The continuity testing of the reinforcement for the cathodic protection requirement shall be
conducted and witnessed by the QC department. The results shall be recorded. Connection
bosses shall be fixed as detailed on the approved drawings.
One side of the formwork shall be erected and braced. A safe means of access to a working
platform as well as working platform shall be erected for this formwork. This access shall allow
the steel fixers, carpenters and concrete crew a safe working area.
All service openings shall be boxed for block outs / ducted onto the formwork.
The height and width of the wall section shall be agreed with EPC Contractor/ Engineer. The
wall height shall terminate near the underside of the roof slab, where the remaining top part of
the wall can be cast along with the roof slab.
The walls shall be prepared and cast in sections not exceeding 6.0m length where a
construction and or contraction joint shall be formed using plywood. After all the inspections of
the preparatory works, the concrete pouring activity shall be carried out in lifts not more than
450 mm layers. This concrete surface at joint location shall be scabbled prior to the next
section is formed formed. Where applicable, the laboratory portion outer wall form shall be
erected with the profile strips prefixed to the formwork. The remaining wall form shall be
erected and braced. A safe means of access to a working platform as well as working platform
shall be erected for this formwork. This access shall allow the steel fixers, carpenters and
concrete crew a safe working area.
The surveyor shall check the alignment of the wall.
The preparatory works shall be checked by the site engineer who then request the QC.
The finished reinforcement and formwork configuration shall be inspected on an ongoing basis
by the Civil Contractor QC department who in turn obtain concrete pouring permission from
EPC Contractor. Having obtained approval, the structural concrete shall be poured by
pumping. Curing shall be carried out according to the specification requirements.
Equipment
Crane.
Concrete Pump.
Vibrators
Hand Tools.
Attachment
None.


Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              18 of



#6

Concrete pipe culverts
Top
Index
Scope
Reference documents
Definitions
Responsibilities
Safety
Method
Equipment
Attachment
Scope
The purpose of this Method Statement is to define the sequence and methodology for the
laying, jointing and testing of the concrete pipe culverts.
Reference documents
Specification
Specification
Drawing No.
Definitions
E                        Engineer
PSM                      Project Site Manager.
CS                       Construction Superintendent
Responsibilities
The CS shall Plan and Resource the concrete lining activities, to ensure that they are
Constructed according to the Drawings and Specification.
The Construction Foreman shall actually execute the works, directing the workforce as
necessary.
Safety
Prior to the commencement of any activities, the labour force shall receive a toolbox talk on the
Project Site Safety requirements. Any process that may have a particular Safety risk, shall be
assessed and addressed as required in consultation with the safety engineer.
Method
Setting Out
The edge co-ordinates of the pipe shall be calculated from the information on the drawing as
well as allowing for the 1:1.5 slope & fixed in such a way that full length of pipes are used
without pipe cutting. The center line and the actual width shall be marked on ground.
Excavation
The trench shall be excavated to the correct width, length and formation by using a Hydraulic
backhoe. Once the bulk excavation is completed, wooden pegs shall be used showing the
elevations marked on them to guide & complete the excavation to required formation levels.
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              19 of



The formation shall be watered and compacted using a plate compactor to achieve compaction
of 90% of MDD in accordance with specification. The compacted formation shall be inspected
and field compaction tested prior to the commencement of the Bedding activity.
Bedding
Once the excavation is completed & approved, Bedding material shall be placed to a thickness
of 150mm, watered and compacted in compliance with the specifications. The compacted
surface shall be inspected, tested and approved.
Pipe Work
The socket positions shall be setout on the Bedding. Manual excavation shall be carried out for
socket portion to ensure that the barrel of the pipe rests firmly on the bedding. It shall also be
ensured that spigot ends remain clean to the same standard as were while installing the
gaskets. The concrete pipes shall be transported from the store to the location of the trench
and gently lowered into the trenches with a crane using belt slings only. The socket end shall
be placed upstream. The pipes shall be laid back to back to the correct orientation. The spigot
end of the pipes shall be cleaned using a cloth with special care taken to clean the recess
which be lubricated with liquid soap following which the gasket placed in position. Supports
shall be placed at one end. The spigot shall be so placed that the gasket is in contact with the
entry taper/bevel at the socket evenly on circumference. The spigot shall then be drawn into
the socket using a 5 tonTirfor. Upon completion of the Jointing operation, the Bedding material
shall be packed below the pipes so that the barrel rests firmly on the bedding and the pipe
doesn‟t move. The top elevation of the pipe shall be checked to ensure that the laid pipe is
accurately placed to the correct alignment and elevations. The operation shall be repeated
until all the pipes are laid. The completed pipework shall be inspected and approved. Each
joint shall be visually inspected from inside the pipe if accessible.
Backfill
Once the pipes have been laid to the True gradient and alignment as described above,
Bedding Material shall be carefully placed along the sides and in between the pipes by means
of a backhoe. The bedding and surround material shall be placed in layers, watered and
compacted until the surround material reaches 300mm above the top of the pipe. Excavated
suitable material shall then be used in compacted layers of 200mm inspected and tested until
the backfilling operations are completed.
A list of Do‟s and Don‟t‟s provided by the manufacturer is attached herewith.
Equipment
Crane 20Ton                           1 No.
Flat Bed Trailor                      Part time
Excavator Backhoe                     1 No.
Trifor 5 Ton                          2 Nos.
Fork lift                             Part time
Plate Compactor                       1 No.
Water Tanker                          Part time
Labour
Foreman                               No. 1
Pipefitter                            Nos. 2
Labourers                             Nos. 4
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              20 of




Attachment
Manufacture‟s datasheet.
#7

Culvert crossings to avenue e and main
highway.
Top

Index
Scope
Reference documents
Definitions
Responsibilities
Safety
Method
Equipment
Attachment
Scope
The purpose of this statement is to define the sequence and methodology for the excavation,
placement of culvert pipes, backfill and reinstatement to the culvert crossings on avenue E and
the main highway next to the retention pond.
Reference documents
Drawing No:
Drawing No:
Definitions
E              Engineer
PSM            Project Site Manager.
CM             Construction Manager.
Responsibilities
The CM shall plan and resource the culvert construction operation, including the permissions
required from all authorities concerned.
The Construction Foreman shall control and monitor these activities, directing the workforce as
necessary.
Safety
Prior to the commencement of any activities, the labour force shall receive a tool box talk on
the project site safety requirements. Any process that may have a particular safety risk, shall
be assessed and addressed as required.
Method
The route of the culvert trench shall be set-out by the surveyor. The existing services such as
the fibre optic cable shall be located and protected. The cable shall be supported across the
excavation, placed within a PVC duct, wrapped with polythene & tied to the support.
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              21 of



The traffic diversion scheme wilth all signs installed shall be implemented according to the
attachment and monitored regularly by the safety department to ensure a smooth traffic
management. Concrete barriers shall be placed at the head of the diversion. The ditch along
the side of the diversion shall be barricaded with nylon rope bearing warning tape.
The initial excavation shall commence at the drainage ditch to the west side of avenue E and
extend across avenue E up to the fibre optic cable location.
The trench shall be excavated using appropriate equipment while dump trucks collect the
surplus excavated earth to be removed from site to the spoil area. Material that is to be reused
shall be stockpiled. The excavated asphalt shall be deposited at the tip area in the pre-agreed
location. Any damage to the existing asphalt shall be repaired during the reinstatement
operation.
The sides of the excavation shall be sloped where the excavation depth exceeds 1.2 m. A
ladder shall be provided for ingress and egress of the excavation. Ladder shall be located
every 8 m if so required depending on length of excavation.
A banksman shall be provided to monitor the excavation machine operations.
The bottom of the excavated trench shall be inspected by the EPC Contractor engineer prior to
the compaction activity commences. All unsuitable material shall be removed.
Inspection and testing of the compaction shall be conducted by the site test laboratory. The
field density test results shall be submitted for approval.
The surveyor shall monitor the line and level of the excavation regularly & provide level pins for
the pipe bedding.

Approved bedding material shall be placed and compacted to the required levels and density
values. The site test laboratory shall conduct the field density tests & reported accordingly.
The concrete culvert pipes shall be placed correctly to the line and level as shown on the IFC
drawing.
The pipes shall be inspected for damage prior to placement. No damaged pipes shall be
placed. The spigot head on the culvert pipe shall be on the up stream end of the pipe. A pair of
nylon strap shall be used to lift the pipes using a 50 ton crane and place the pipes correctly in
to the trench. Backfill material shall be placed around the pipes in layers of 150mm thickness
duly compacted & tested by the laboratory. Backfill operations shall continue up to the existing
road formation level.
When the backfill activity is completed, asphalt repair to the existing highway shall be
conducted & avenue E road construction shall be reinstated. The traffic management scheme
shall be removed to allow the re-use of avenue E.
A temporary security fence outside the existing RRD area shall be erected to allow the culvert
construction to continue east towards the retention pond. The temporary security fence shall
be erected to the agreement and requirements of the security police. When this activity is
completed and approved by the security police, the existing security fence can be cut and
rolled back sufficiently to allow the construction activities to be conducted.

The next section for the culvert trench shall be excavated taking care of where existing
services have been exposed to be well protected.
The trench formation shall be inspected, compacted and tested as previously described.
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              22 of



Pipe bedding shall be placed, compacted and tested as previously described.
The pipes shall be installed within the trench after inspection for transit damage is completed.
Backfill around the pipes shall be placed, compacted and tested.
The backfill shall be reinstated above the pipe surround up to existing ground level.
Reinstatement of any existing services shall be done. The fibre optic cable shall be left
protected by the PVC duct and polythene sheet, then surrounded with concrete.
The existing security fence shall be replaced. The existing fabric shall be re-erected onto the
existing poles which shall be re concreted in position. The barbed wire shall be re placed using
new material where required.
The temporary security fence shall be removed.
The final section of the culvert trench shall be set-out and excavated in the same sequence as
the previous sections.
The compaction and testing of the pipe bedding shall be carried out.
The placement of the pipes to the correct line and level shall be carried out.
The backfilling of the pipe surround shall be conducted. The reinstatement of the backfill above
the pipe surround material shall be conducted. The site test laboratory shall conduct the field
density testing. The inlet and outlet chambers of the crossing shall be constructed. Refer to the
method statement for chambers. This procedure shall be similarly followed in principle for any
other culvert crossings on avenue E.
Equipment
Excavators.
Dump trucks.
Compactors.
Attachment
None.
#8

Placing concrete on service
Water tank 58-tk-205 foundations
Top

Index
Scope
Safety
Method
Equipment
Attachment
Scope
The purpose of this method statement is to define the sequence and methodology for the
placing of concrete on service water tank foundations.
Reference documents
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              23 of



Specification
Definitions
E             Engineer
PSM           Project Site Manager.
CM            Construction Manager.
Responsibilities
The CM shall plan and resource the concrete repair activities, to ensure that they are
implemented according to this method statement.
The Construction Foreman shall monitor the concrete repair activities, directing the workforce
as necessary.
Safety
Prior to the commencement of the concrete pour, the labour force shall receive a tool box talk
on safety requirements with special care taken to ensure adequate lighting arrangements are
made. We propose to use 2 Nos. Tower lights each with 4 X 1000 Watts bulbs. Accers
platforms shall be provided all around the ground beam on the outside formwork, 2 Nos.
Aluminium ladders shall be placed at opposite ends to reach the Accers platforms from the
ground levels. The accers platform shall be provided with Hand Rails all around.
Method
Preparatory works shall be carried out for the form works in circular profile for which due
provisions shall be made for the specialist form. This form shall be well supported & anchored
to resist ecpected forces during the our. As parallel activity, rebars shall be placed & fixed in
the correct positions duly inspected.
It is proposed to cast the Ring beam in two pours. Stopend forms shall be placed at opposite
locations across the full width and depth to establish construction joints. The concrete shall be
poured onto the section in one go 300 to 450 mm high around and compacted with suitable
vibrators. Care shall be taken to ensure that concrete is placed and compacted in its final
position within the time permissible form the time of batching to the time it should be
compacted in accordance with the concrete production specification that may be generally 1 to
2 hours. Concrete delivery shall be planned accordingly to quantity & duration of pour to
enable a smooth concreting operation. Concrete shall be continually poured from the start to
the concrete por finish. No cold jointshall be allowed to form. All flash setting shall be avoided
by keeping the rebars lower than the air temperature. Proper vibration shall be effected. After
the concrete is completed, proper method of curing shall be carried out & continued for
specified number of days. All tests for on site concreting shall be conducted by the RMC
laboratory staff duly recorded.
Equipment
Concrete pump, concrete trucks, vibrators,
Attachment
None.

#9

Concrete repair
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              24 of




Top
Index
Scope
Reference documents
Definitions
Responsibilities
Safety
+Method
Equipment
Attachment
Scope
The purpose of this method statement, is to define the criteria for the concrete repair to all
structures.
Reference documents
Specification
Definitions
E             Engineer
PSM           Project Site Manager.
CM            Construction Manager.
Responsibilities
The CM shall plan and resource the concrete repair activities, to ensure that they are
implemented according to this method statement.
The Construction Foreman shall monitor the concrete repair activities, directing the workforce
as necessary.
Safety
Prior to the commencement of any activities, the labour force shall receive a tool box talk on
the project site safety requirements. Any process that is adopted that may have a particular
safety risk, shall be assessed and addressed as required.
Method
Upon removal of the formwork, the concrete surface shall be inspected by the Site engineer &
foreman to check surface defects.
Where no surface imperfections have occurred, the concrete surface shall be cured according
to the relevant procedure. Minor defects as described in A – D below shall be repaired as soon
as practical. More significant defects as described in E – H shall be subject to joint inspection
/ agreement between Civil Contractor, EPC Contractor and Company.
A.
Pin holes / blow holes
Where small defects to the concrete surface has occurred such as pin holes or holes smaller
than 3mm in diameter or depth, the surface shall be repaired using Nitomortar FC with an
approved bonding agent. This surface repair shall be conducted as soon as the formwork is
removed whilst the concrete is still green. The repair shall then be cured in accordance with
manufacturer‟s instructions or agreed procedures using water or curing agent as appropriate.
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              25 of



B.
Sand runs / scouring
Water movement inside the shutter can result in a streaky appearance giving loose sandy
finish. Where this occurs, any loose material shall be removed by stiff brushing and then
repaired as described in A above.
C.
Plastic shrinkage cracks
Cracking caused by plastic shrinkage due to inadequate curing and protection of horizontal
surfaces usually results in a series of diagonal cracks. These should be repaired by brushing
dry cement powder directly into the cracks while the concrete is less than 3 days old and
covering with damp hessian.
D.
Minor misalignments (Typically Less than 2cm)
Misalignments due to shutter movements etc, should be ground back to provide a smooth
transition between areas. Where occurring at joints between panels, the ground profile length
should be 2-3 times the size of the maximum misalignment. Following grinding, the surface
should be reinstated as in A above. Care should be taken to ensure that concrete cover is
maintained per specifications at all times.
E.
Honey combing / segregation / minor voids
The repair shall be conducted as soon as the formwork is removed and the repair method
agreed with EPC Contractor / Engineer. It shall require chipping the repair area free of laitance
and exposing any voids. The repair area shall then be soaked, an approved bonding agent
applied followed by working on with an approved mortar such as Master Flow 544 before the
area dries out.. The materials shall be mixed using the bonding agent and not water. The
mixed material shall be trowelled firmly into the repair area. Incase, the depth of the repair
exceed 15mm, the repair shall be conducted in two layers providing a scratch coat on the first
layer. The repair shall then be cured in accordance with the agreed procedure using water or
curing compound as appropriate.
F.
Major voids (Typically Deeper than 5cm)
This repair shall consist of chipping the affected area to remove any laitance and voids. Where
reinforcement is exposed in a void, the surrounding concrete shall be chipped away to provide
adequate space to place fresh concrete around the reinforcement including removal of all soft
concrete. (Note- a distance of one and a half times the stone size must be allowed around all
exposed reinforcement). Formwork shall be provided to retain the fresh concrete. The chipped
area shall be soaked in and primed with a bonding agent. The bonding agent shall not be
allowed to dry. Fresh concrete of the same grade as the surrounding concrete shall be used to
fill in the void. The repair shall be water cured along with the parent concrete. The surface
finishes to the repair shall be as the same standard as the surrounding concrete.
G.
Plastic settlement cracks
Cracking caused by settlement of concrete usually in deep lifts or at changes in section can
result in a series of cracks which mirror the reinforcement pattern in horizontal surfaces or
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              26 of



appear to arch on vertical surfaces. Any such cracks should be chased out to a depth of 10-
15mm and filled with an epoxy mortar such as Nitomortar FC as in A above.
H.
Pourous / spongy surface
Where inadequate vibration and poor finishing techniques have caused excessive bleeding,
horizontal surfaces can appear spongy and pourous. In this case all affected surfaces should
be ground back to good concrete usually only 2-3mm below the surface. The surface should
then be reinstated using Nitomortar as in A above. This type of defect often occurs with plastic
settlement cracks which should be treated as In G above.

All repairs noted above shall be recorded on the post-pour inspection form (QCF). It is not
necessary to raise a non-conformance report provided the repairs are carried out as indicated
above and agreed with EPC Contractor where necessary. Any repairs not covered by the
above procedure shall be dealt with on a case-by-case basis and agreed with EPC Contractor
and Company before commencing repairs.
Equipment
Hand Tools.
Attachment
None.
#10

Construction of pipe rack bases
Top
Index
Scope
Reference Documents
Definition
Responsibilities
Safety
Method
Equipment
Attachment
Scope
The purpose of this method statement is to define the sequence and methodology for the
Construction of the pipes rack bare foundations.
Documents
Specifications
Drawing No:
Definitions
E                        Engineer
PSM                      Project Site Manager
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              27 of



CM                       Construction Manager
CS                       Construction Superintendent
Responsibilties
The CS shall plan and resource the Construction of Pipe Rack Bases activities, to ensure that
they are Constructed according to the Drawings and Specification.
The Construction Foreman shall actually execute the works, directing the workforce as
necessary.
Safety
Prior to the commencement of any activites, the labour force shall receive a toolbox talk on the
Project Site Safety requirements. Any process that is adopted that may have a particular
Safety risk, shall be assessed as required.
Method
It is proposed to cast the pipe rack bases and the columns at actual locations at site. The
method of Construction of the pipe rack bases can be summarized in the following activities.
Setting Out
Excavation
Blinding Concrete
Formwork
Steel Reinforcement
Concrete Construction
Concrete Protection
Construction of Columns with Anchor Bolts
Backfilling
Grouting
Setting Out- Pipe Rack Bases
The center lines of the Anchor bolt group shall be set out and offset provided 2m on either side
of the foundation as reference line for blinding using manual methods of setting out.
Excavation
The bases shall be excavated with excavator, sides trimmed to avoid caving in. The formation
shall be compacted, inspected, field tested and approved prior to the commencement of the
blinding.
Blinding Concrete
The formation area to receive the blinding shal be prepared to the design levels & profiles. C20
PBFC grade concrete shall be placed to a minimum thickness of 50mm and the top surface
smoothened by steel trowel. Curing shall be carried out for the blinding concrete for at least
two days. Prior to the placement of the precast pipe rack base on it, mass concrete infill shall
be placed as required in accordance with the drawings as necessary.
Site Precast Yard for foundations
A precast yard shall be constructed on site at the location indicated in the attached sketch.
A wind shield fence 2m high shall be erected on the Northern boundary as indicated in the
proposed location in accordance with clause ………………… of the specification.
Steel Formwork
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              28 of



Steel Forms as shown in the attached sketch shall be used for casting the pipe rack base
foundations. The forms should be easily struck as well placed in position.
Separate forms shall be used for the bases and columns . The base slab formwork shall have
100mm high suspended kicker.
Fosroc reebol mould release oil shall be used. The template for anchor bolts for piperack base
type1, 3 & 5 shall be a 100mm wide strip of steel plate across the width of the column steel
formwork at the top. The template for piperack type 2, 4, 6, & 7 shall be similar in Construction
type with 2 plates and a connecting piece.
Anchor Bolts & Steel Reinforcement
Steel Reinforcement cut and bent to the required shape and size shall be available on site.
Reinforcement shall be timely fixed in place on the casting beds.
Lifting Hooks
Lifting hooks shall be inserted into the correct location & properly fastened so as not to be
dislocated during concrete pouring.
Casting Concrete
Formwork applied with a fresh coat of mould release oil shall be placed in position around the
already assembled steel reinforcement. Lifting recess plugs shall be installed in position with a
Template. All supports shall be fixed in position. Inspection shall be conducted to the ITP
requirement. The Base shall be poured and compacted with vibrators. The surfaces shall be
smoothened with steel trowel. Curing shall ne carried out. Formwork for the column shall be
installed the following day. The plumb and alignment shall be checked and the anchor bolts
with sleeves installed and held in position by the template . The widths of the template shall be
kept to the minimum to allow room for concrete vibrators. Once the column is cast, the
formwork shall be stripped after 36hrs and the concrete cured for a minimum period of 7 days .
Protective Coatings
Once the curing is completed as stated above, the polythene sheets and hessian shall be
removed and the concrete faces allowed to dry for atleast 24hrs during which time minor
repairs such as filling up of blow holes etc. shall be carried out. The faces shall be wiped clean
with a wet sponge and surface prepared to receive the first coat of protective painting.
Fosroc Nitocote ET 402 shall be mixed with a slow speed electric drill and spray applied with
an airless sprayer equipment to the required thickness of 1mm as a single high build coat in
accordance with the manufacture‟s instructions.
The column and the top sides of the boxes, vertical faces shall be painted as described above.
The bottom of the base slab shall be left without painting.
Traceability
The pipe rack bases shall be numbered and the date & time of casting marked on the
concrete.
Lifting, Transportation and Installation
After completion of the curing, certified cranes of required capacity shall be used to lift the pipe
rack base from the casting bed to the flat low bed trailor. The bases shall be transported to the
actual location of installation.
On location preparatory pf preceeding activities shall be completed prior to the transportation
of the bases. The screed shall be cast accurately to the actual dimension of the bone of the
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              29 of



pipe rack foundation. Using a jack of adequate capacity, the unit shall be moved to the correct
position accurately. The crane shall be used to lift the pipe rack base from the Trailor down
onto the screed surface.
The position of Anchor bolts shall be rechecked with a Theodalite and accuracy of the
installation certified by a surveyor.
Back filling
Once the pipe rack base is installed, Backfilling with selected suitable fill material shall
commence. The fill material shall be pre mixed with water 3% more than the optimum moisture
content for the daily requirement. Layers of premixed fill material shall be placed to a thickness
of 200 mm and compacted properly. The compacted surface shall be inspected, field tested
and these operations repeated until the Backfilling operations are completed.
Anchor Bolts shall remain protected with PVC sleeves until completion of the Backfilling
operations and only exposed at the time of installation / erection of steel works.
Equipment
Crane 50Ton                                        2 No.
Flat Bed Trailor 40 Ton                            1 No.
Excavator Backhoe                                  1 No.
Plate Compactor                                    1 No.
Water Tanker                                       1 No.
Labour
Casting Engineer                                   1 No.
Placing Engineer                                   1 No.
Casting Foreman                                    1 No.
Placing Foreman                                    1 No.
Carpenters                                         20 Nos.
Steel fixers                                       30 Nos.
Masons                                             20 Nos.
Laborers                                           40 Nos.
Attachment
Manufacture‟s datasheet.

#11
Excavation in Operating Authority controlled areas
Top

Index
Scope
Reference Documents
Definition
Responsibilities
Safety
Method
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              30 of



Equipment
Attachment
Scope
The purpose of this method statement is to define the methodology that shall be implemented,
for construction activities that shall be conducted in areas under Operating Authority control.
These areas shall primarily be the easement areas.
Documents
All applicable Operating Authority easement drawings.
All applicable EPC Contractor project Drawings.
All applicable EPC Contractor project specifications.
Definitions
E                        Engineer
PSM                      Project Site Manager
CM                       Construction Manager
CF                       Construction Foreman.
Responsibilities
The CM shall plan and resource the construction activities, to reflect the conditions imposed
upon the “Permit to Work” system.
The CF shall actually execute the construction activities, directing the workforce as necessary.
Safety
Prior to the commencement of any of the construction activities, the labour force shall receive
a toolbox talk on the Project Site Safety requirements. Any activity that is conducted that may
have a particular Safety risk, shall be assessed as required.
Method
The Construction Manager shall assign an Engineer and Construction Foreman to be
responsible for the relevant activities.
The Engineer shall be responsible for producing a method statement for the activities to be
carried out. This method statement shall contain the procedure defined below.
When the method statement has been agreed with EPC Contractor, a work permit covering the
work activities within area of work shall be obtained from Operating Authority & duly registered
into the work permit log.
The Work area shall be surveyed to establish existing services location using the Operating
Authority easement drawings and the cable detector. These services shall be exposed by hand
dug trenches along the route. Where the existing service may cross the route of the proposed
work activity, adequate protection and warning of that existing service shall be provided.
The method of excavation for the work activity shall be defined upon the work permit. Where
mechanical methods are accepted, a banksman shall be deployed with all mechanical
excavation equipment to check for any existing service and advise the operator of the
excavation machine.
The excavated material where possible shall be stockpiled in a controlled area location. Any
unsuitable material shall be removed from site to the spoil area immediately.
Where soil conditions dictate, the sides of the trench shall be sloped.
During the duration of the work activities, the site shall be kept clean.& tidy
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              31 of



The Civil Contractor QC department shall conduct the required inspection and test regime
required under the ITP.
Upon completion of the work activity, all rubbish shall be removed from the work site. The
easement area shall be left graded.
Equipment
Cable scanner.
Dump trucks
Excavators as applicable.
Compactors.
Attachment
Checklist MS
#12

Construction of main substation
Top

Index
Scope
Reference Documents
Definition
Responsibilities
Safety
Method
Equipment
Attachment
Scope
The purpose of this method statement is to define the sequence and methodology for the
Construction of the Main Substation.
Documents
Specifications
Definitions
E                        Engineer
PSM                      Project Site Manager
CM                       Construction Manager
CS                       Construction Superintendent
Responsibilities
The CS shall plan and resource the Construction of Main Substation activities, to ensure that
they are Constructed according to the Drawings and Specification.
The Construction Foreman shall actually execute the works, directing the workforce as
necessary.


Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              32 of




Safety
Prior to the commencement of any activities, the labour force shall receive a toolbox talk on the
Project Site Safety requirements. Any process that is adopted that may have a particular
Safety risk shall be assessed as required.
Method
This method statement details only the Structural Concrete works. Finishes, Steel Sheet
Roofs, Ladders, Access Platforms, Internal and External Insulation, Galvanised Steel Mesh etc
are not Included in this Method Statement.
The Main Substation structure is to be constructed in the following stages.
Stage 1:
Earthworks, blinding, waterproofing, screed protection up to defined Elevation
Stage 2.
Footing pad construction including kicker up to 100mm above top of footing.
Stage 3.
Stub columns / walls including anchor bolts for galvanised screen mesh up to underside of
floor slab / ground beam – defined Elevation.
Stage 4.
Ground slab of HVAC room including anchor bolts for ladder / access platforms TOC
Stage 5.
Floor slab for Main Building TOC (Top of Concrete)
Stage 6.
Wall construction up to bottom of roof slab / roof beam elevation
Stage 7.
Roof slab construction including kicker for parapet wall.
Stage 8.
Parapet wall construction.
The Transformer Bays and the Foundation are to be constructed in the following sequence:

Stage 1
Earthworks, blinding, waterproofing, screed protection.
Stage 2.
Footing pad construction and kicker 100mm above the top of footing including water stop bar
for transformer bay partition wall and boundary wall footings.
Stage 3.
Transformer bay partition walls full height of 10m including cast in anchor plates for Roof truss.
Stage 4
Transformer bay boundary wall including cast in sleeves for Fence Posts.
Stage 5.
Transformer foundation bases including bases for Sump and Valve Pit.
Stage 6.
Gravel Fill between foundations and walls.
Stage 7.
Steel Roof Trusses and Roof.
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              33 of




Setting Out
Grid line (1) to (13) and (A) to (D) shall be offset 3m away from the edge of the walls. The
points shall be marked by a nail driven on top of wooden pegs driven into the ground and set in
concrete.
STAGE I
Excavate whole area to Formation Level.
Further excavate for transformer bay partition wall. Foundations to required elevations.
Create Access ramp at either short ends to allow Heavy equipment to get in and out.
Using grader and 12T Formation roller, Scarify and compact formation to elevation + 20mm.
Test for degree of Compaction and get approved.
Set out grid lines (1) – (13) and (A) to (D). Use steel pins to be 2m away at outer edge of
Concrete face.
Mark Grid lines with chalk powder.
Use Timber reapers to construct edge forms and place blinding Concrete to Elevation 98.50
200mm wider than required. Cure the concrete according to specifications requirements.
Apply waterproofing membranes in sections one day prior to fixing formwork for base pads.
STAGE II
Place Formwork directly on Waterproof membrane.
Formwork height shall be the height of Footing Pad + 30mm for protection screed. Timber shall
be placed on top of the base formwork to act as kicker for Columns / Walls.
Place Steel Reinforcement with Starter bars for Columns / Walls.
Place timber reapers on bothfaces of the formwork for Contraction Joint at location indicated in
the attached sketch No. 1. Care would be taken to ensure that contraction joints in west wall
would be hidden behind GRC Facia
Care to be taken to ensure that waterbars are placed at the right position on the edge of Pad
Concrete for Transformer Bay partition walls and East wall.
Isolated footing bases shall be cast. Bases for wall foundations shall be cast as per sequence
shown in attached sketch no. 2.
STAGE III
Place Reinforcement for Stub Columns and Walls up to Floor Level.
Place Formwork for Stub Columns and walls up to Floor Level.
Vertical Construction Joints shall be located at same positions as indicated in the attached
sketch No. 1. The distance from the corner shall not exceed 4.5m and the distance between
intermediate ones shall not exceed 6m.
Horizontal Construction Joints shall be at locations shown in Drawing No. as described in this
Method Statement.
Cast Stub Columns and Walls up to underside of Floor Slab.
STAGE IV & V
Install Formwork for floor beams and floor slab including 100mm Kicker for main walls.
Construction Joints for floor slab shall be as shown in attached sketch No. 3.
Install Reinforcement for floor beam and Floor slab.
Place steel channels and Box outs for openings in floor slab for switchgear control panels.
Penetration sleeves / ducts shall be boxed out for cables and utility services

Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              34 of



Cast Floor slab in alternate panels. Construction Joints shall be located within the middle third
point of slabs and beams as shown in the attached sketch No. 2.
STAGE VI
External Formwork for vertical walls shall be placed in position, aligned and supported.
Box outs for Bus duct penetration, rebates for Personnel and Equipment, Blast door frames,
Air Conditioner openings and others shall be Boxed out.
Cast in items such as Anchor plates for Roof truss shall be fixed in position.
Timber reapers for Contraction Joints shall be fixed to the outer formwork face.
Steel Reinforcement shall be installed as required.
Inner Formwork not exceeding 6m lengths shall then be placed after inspection approval of
rebars up to the bottom of Roof slab level. Design calculations included as attached.
The wall section shall be cast. Formwork design is similar to the ones used at Seawater surge
basin. The rate of pour shall not exceed 2m vertical height / hr.

STAGE VII
Roof Slab scaffolding shall commence even as the wall construction activity is in progress on
completed sections of walls.
Roof Slab Construction Joints are shown in the attached sketch.
Suspended kickers shall be placed for parapet wall.
The Roof slab shall be cast. A set of four cubes shall be taken for each pour.
Scaffolding shall not be removed for 14days and until the full design strength of concrete is
reached. Cubes shall be crushed for 7,14 and 28 day strength.
STAGE VIII
Rainwater chutes shall be boxed out on parapet wall formwork. Reinforcement shall be placed
and concrete cast in the same manner as for main wall.
CURING
Every pour be it a footing, stub column, wall, floor or roof, shall be wet cured with Hessian,
covered with polythene sheet and kept wet for a minimum period 14 days in accordance with
the specification. 2nos, 5000ltrs. Capacity water tanks in elevated platforms shall be provided
for round the clock curing operations.
Approved Curing Compound shall be used in Roof Soffits.
Equipment
Excavator / JCB
Transit Mixer
Crane 20 T
Attachment
Sketch No. 1: Showing locations of Contraction Joints.
Sketch No. 4. Showing Concrete Pouring Sequence.
Sketch No. 2. Showing Construction Joints for floor slab.
Sketch No. 3. Showing Construction Joints for Roof slab.
#13

Removal of hazardous materials
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              35 of




Top
Index
Scope
Reference documents
Definitions
Responsibilities
Safety
Method
Equipment
Attachment
Scope
The purpose of this method statement, is to define the procedure that shall be implemented,
for the investigation, quantification and disposal of the hazardous material upon the site.
Reference documents
Operating Authority regulations.
Bechtel HSE Manual.
Definitions
PSM Project Site Manager
GE  Geotechnical Engineer.
IS  Infrastructure Superintendent.
ST  Survey team.
Responsibilities
EPC Contractor shall coordinate with all concerned authorities, for their approval of the
hazardous material disposal.
The PSM shall plan, resource and control the activities required for the orderly execution of the
hazardous material disposal.
The IS shall monitor the activities, in compliance with this procedure.
The GE shall ensure accurate reporting of the materials.
Safety
Prior to the commencement of any activities, the workforce shall receive a Tool Box Talk on
the project site safety requirements. PPE where appropriate shall be provided to those
persons who shall come into contact with any hazardous materials.
Method
The hazardous material shall be located and identified upon the site. The ST shall record these
details upon a site sketch.
The GE and IS shall inspect the hazardous material visually and complete an inspection
report.
An accurate description of the material shall be provided. Where elements such as barrels are
part of the hazardous material, the identifying marks upon the barrel shall be checked. Where
appropriate, samples shall be taken to verify the content.
Where such liquids have leaked into the soil, samples of the soil shall be taken to verify the
amount of contamination.
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              36 of



The ST shall assist the GE and IS to establish the extent of contamination. Trial pits may be
dug to visually gauge the penetration of contamination. Samples of soil from these pits shall
verify the content and absorption if any of the contaminant. The ST shall record the details.
Upon receipt of the laboratory results that verify the analysis of the contaminant, a specific
safety plan if required, shall be prepared for the safe handling of suspect material or soil. Any
precautions that are not defined within this method statement but essential shall be taken up.
The solid items of contaminated material shall be lifted by loader shovel into the rear of a tipper
truck. An inventory of the items loaded into the truck shall be produced. A permission shall be
obtained from the operating authority for the purpose of disposal of hazardous material waste
into a designated area. The truck covered with a dust preventive sheet shall transport the
material to the approved Operating Authority waste disposal site in the industrial area. The
contents shall be offloaded in accordance with the facility rules and regulations monitored by
the EPC Contractor representative.
This process shall continue until all items of waste are removed from the site.
The existing soil material that is contaminated shall be clearly marked with pegs. Using a
loader shovel, the material shall be excavated and loaded into a tipper truck. The truck shall be
covered whilst transporting the soil to the mixing area where the soil be stockpiled. This
process shall continue until all contaminated soil is removed to the satisfaction of the GE.
The stockpile of contaminated soil shall be lightly spread across the disposal area at levels
above the water table. This shall be achieved by using loader shovel and grader. The layer
thickness shall not exceed 150mm. A grader shall now mix this layer with the layer of
uncontaminated material below. This shall have the affect of dispersing the material. A normal
layer of uncontaminated material shall be placed upon the top of this mixed material. If
required, a further layer of contaminated material shall be spread over this layer of material
until the stockpile is depleted. This layer shall be mixed with the layer below as described
previously.
A topping layer of uncontaminated material shall be placed on top of all mixed material.
The GE shall satisfy himself that the layer thickness is minimal and the material is adequately
mixed with the layer below.
Upon completion of the removal of the hazardous material, the GE shall prepare a report that
identifies the material disposed as well as the areas of disposal.
Equipment
Excavator.
Grader.
Dump trucks.
Attachment
ITP No:
QCF, Visual inspection Report.
#14




Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              37 of




Construction of                                                                         floor                           slab                          central
control building
Top
Index
Scope
Reference Documents
Definition
Responsibilities
Safety
Method
Equipment
Attachment
Scope
The purpose of this method statement is to define the sequence and methodology for the
Construction of the floor slab to the Central Control Building.
Documents
Grade Slab General Arrangement
Grade Slab Sections
Foundation Details Penetration
Definitions
PSM           Project Site Manager
CM            Construction Manager
CS            Construction Superintendent
Responsibilties
The CS shall plan and resource the Structrual Backfill activity to achieve the required
compaction as per the specification. The site test laboratory shall conduct and verify the
compaction crireria.
The surveyors shall be responsible for setting out the exact levels of fill and concrete up to
designated drawings.
The construction Foreman shall actually lead the execution operations by directing all Foreman
and workforce as necessary.

Safety
Prior to the commencement of any of the required activities, the Labour force shall receive a
tool box talk on the Project Site Safety requirements.
Method
The slab on grade level shall be casted over compacted fill by using a separation Polyethylene
Membrane. The slab is divided into two main portions.
The low level portion at EL shall have a smooth level finish in order to receive the bases of the
access panel system. This portion is to be cast in panels to give the required joints as specified
on the drawing.
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              38 of



The high Level portion at EL shall be cast in panels according to the required joints shown on
the drawings. The surface finish for this section shall be rough since Tiling and flooring
systems are to be applied. In Electro-Mechanical rooms the surface finish shall be smooth to
receive the epoxy coating finish as specified.
General Curing shall be carried out to the norms of the Project Specifications.
All cable trenches and separating Wall shall be cast up to levels and dimensions specified on
related drawings.
Equipment
Crane 50Ton                2 No.
Flat Bed Trailor 40 Ton    1 No.
Excavator Backhoe          1 No.
Plate Compactor            1 No.
Water Tanker               1 No.
Labour
Casting Engineer           1 No.
Placing Engineer           1 No.
Casting Foreman            1 No.
Placing Foreman            1 No.
Carpenters                 20 Nos.
Steel fixers               30 Nos.
Masons                     20 Nos.
Laborers                    40 Nos.
Attachment
None.

#15

Mortar for blockwork
Top
Index
Scope
Reference Documents
Definition
Responsibilities
Safety
Method
Equipment
Attachment
Scope
The purpose of this method statement is to define the sequence and methodology for the
production of mortar for use with the blockwork activities.
Documents

Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              39 of



Masonary
Definitions
PSM             Project Site Manager
CM              Construction Manager
CS              Construction Superintendent
Responsibilties
The CS shall plan and resource the blockwork activity, to achieve the required combination of
workmanship and material quality.
The construction Foreman shall actually lead the execution operations by directing all the
workforce as necessary.
Safety
Prior to the commencement of any of the required activities, the Labour force shall receive a
tool box talk on the Project Site Safety requirements.
Method
The block supplier shall be submitted for approval to EPC Contractor.
The sand aggregate for the mortar shall be submitted and approved by EPC Contractor.
Potable water from the Operating Authority source shall be used for mixing sand and cement.
Storage of materials shall be on appropriate seggregated suitable areas adjacent to the work
place with no possibility of contamination or deterioration of the materials.
Mortar shall be mixed mechanically on site using standard boxes for measuring sand for each
batch. The amount of water required shall also be defined depending on water cement ratio.
The ingredients shall be mixed thouoghly until a uniform mix is achieved.
Mix production quantiry in one batch shall be limited to a volume which can be consumed
within the initial setting time of cement. The remixing of martar by adding additional water shall
not be permitted.
Once the mortar is produced, it shall be taken to the workplace and used within specified
setting time that is generally 2 hours of adding into the mixer.
Equipment
Cement mixer
Gauge boxes
Hand tools.
Attachment
None.
#16

Control of camp sewage system
Top

Index
Scope
Reference Documents
Definition
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              40 of



Responsibilities
Safety
Method
Attachment
Scope
The purpose of this method statement is to actions that shall be implemented to monitor and
control the sewage holding tank status, so that overflow is avoided.
Documents
Method statement Waste Management.
Definitions
PSM             Project Site Manager
CB              Camp Boss
TM             Transport Manager.
Responsibilities
The PSM shall be responsible for the implementation of the preventative measures.
The CB shall execute the required monitoring and record keeping of the investigation.
The TM shall ensure the provision of the disposal tankers as and when required.
Safety
All relevant safety issues including hygiene precautions shall be implemented, monitored and
maintained for this activity. The site safety department shall monitor the sewage disposal
areas.
Method
A new water meter to record water usage shall be installed prior to the water storage tanks.
For the next one month, regular readings at specific times shall be recorded to establish water
requirement trends.
The information collected from this exercise shall help to understand the peak demand periods
which also define the sewage disposal requirements.
In parallel to this water input recording, a survey of the sewage holding tanks filling trends shall
be established.
A tank volume indicator system shall be installed at every sewage holding tank.
This indicator system shall consist of a visible indicator rod. Based on a float system, the rod
shall raise up as the holding tank fills. This visual system shall remind the CM to organise the
emptying of the tank. Data obtained from the tanker drivers on number of loads discharged,
shall help verify the water meter quantity to establish leakage‟s.
The existing provision for the trucking of the sewage waste shall be monitored. The fleet
capacity shall be increased as required based upon the results of the survey.
A review of the collected data shall be conducted after one month to supplement existing
operational criteria as required. The responsibility for compiling the information shall be with
the camp boss who ensure that water consumption is regularly monitored, that areas of water
abuse are identified, that holding tank emptying schedule established as well as formulating
measures to conserve and re-cycle water wherever possible.
Initial trucking capacity that is dedicated to the sewage disposal activity is „two trucks‟. These
trucks operate on both suction fill and pump fill systems.

Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              41 of



The survey shall review and confirm the required trucking levels needed to service the holding
tanks.
Attachment.
N / A
#17

Structural steel-piperacks
Top
Index
Scope
Reference documents
Definitions
Responsibilities
Safety
Method
Equipment
Scope
The purpose of this Method Statement is to define the sequence and methodology that shall
be implemented for the Erection of the steel structure piperacks.
Reference Documents
Specification Grouting
Specification Steel Structure Fabrication
Specification Painting
Specification Galvanizing
Specification Project Preservation and Export Packing
Relevant IFC drawings.
Definitions
CM                       Construction Manager.
CS                       Construction Superintendent .
EF                       Erection Foreman.
Responsibilities
The CM shall plan and resource the steel structure erection activities, to ensure that they are
implemented according to this procedure, with the correct equipment resources.
The CS shall ensure that all safety requirements are implemented and explained to the
erection workforce. The CS shall control the day to day activities
The EF shall control the workforce ensuring the full implementation of this method statement
including all safety measures.
Safety
Prior to the commencement of any activity, the labour force shall receive a Toolbox Talk on the
Project Site Safety Requirements. Any process that is adopted that may have a particular
Safety risk, shall be assessed and addressed as required.
The use of cranes shall be assessed and all safety regulations enforced.
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              42 of



Men working at height shall be equiped with the required personal safety equipment
Method
Materials Receivables.
All Structural steel material to be used for permanent works shall be received on site in the
appropriate laydown area. All tems shall be inspected to conduct a check of the delivery
against necessary shipping documents.
All structural steel members shall be checked for quantity, quality and identification.
Then all materials shall be properly stored and protected.
Concrete Foundations.
The surface of the concrete foundation shall be prepared in accordance with the specification,
to receive grout.
All concrete foundations on which the steel structures are to be erected shall be released by
the QC department upon completion of the civil activity.\\\\
Fasteners (Bolts, Nuts & Washers).
Upon receipt on site of the fasteners, a minimum of one sample (1bolt, 1 nut,& 1 washer) shall
be selected and tested by an independent laboratory to confirm specification conformance.
Assembly Of Grid Frames
Material for the necessary grids shall be placed near to the area of erection. This shall be
carried out using a suitable trailer & a 50 ton crane.The grid frames for both rows (A&B) shall
be assembled. All bolts, washers and nuts shall be fitted, fastened and tightened.
Erection Of Columns \ Grid Frames.
Stainless steel shim plates to the correct thickness of approx. 25mm shall be placed at the
center of the foundation column between the holding down bolts. The shim plates shall be
retained in position permanently by surrounding with mortar to avoid shim displacement during
the erection of the columns. The shim placed on the foundation shall be embedded in mortar
bed such that the top of the shim is level in all planes.
The grid frames shall be installed leveled and plumbed on the foundation bases. Stay ropes
shall be provided to maintain stability until such time when the horizontal members are
connected. The stays shall be secured to purpose made anchor plates attached to adjacent
foundations. Foundation bolts shall be only hand tightened. (Necessary tightening or torquing
shall be done later after grouting).
Horizontal members and the bracings that interconnect these grid frames shall be assembled
and erected.
The assembly of Verticals and Horizontal members shall be in sections. On completion of each
section with all bolts and nuts in place and tightened, the final level and alignment shall be
checked and inspected.
Grouting
After the structural steel frame assemblies have been inspected by the QC department, the
application of grouting shall be carried out according to the Specifications & manufacturer‟s
instructions.
Equipment
Crane 30Ton\ 50 Ton
Flat Bed Trailor to transport fabricated members to the location at site
Fork lift – for minor movement of steel members
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              43 of



Guy ropes and tensioning equipment
Man baskets whenever required
Scaffolding (Movable & Non-movable Types)
Air Compressor
Impact Wrench
Welding Generator( if required)
Gas Cutting Equipment (if required)
Portable Grinding Machines
Portable Drilling Machines

Exclusively written by PEng Suraj Singh
#18
Compressors‟ structures
RCC column plate inserts
Top
Index
Scope
Reference Documents
Definition
Responsibilities
Safety
Method
Equipment
Attachment
Scope
The purpose of this method statement is to define the sequence and methodology that shall be
implemented for the inclusion of RCC column plate inserts.
Documents
Specification
Drawing No:
Definitions
PSM           Project Site Manager
CM            Construction Manager
CS            Construction Superintendent
FM            Foreman
Responsibilities
CM shall plan and resource the required materials ensuring that these are implemented
according to this procedure.
CM shall ensure that all the Safety requirements are implemented and explained to the
relevant work force and control the day to day activities.
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              44 of



CS shall ensure the implementation of technicalities involved.
FM shall control the work force ensuring the full implementation of the procedure.
Safety
Prior to the commencement of any activites, the labour force shall receive a toolbox talk on the
Project Site Safety requirements. Any process that is adopted that may have a particular
Safety risk, shall be assessed as required.
Method
    1.     Place & fix the column reinforcement be in design locations.
    2.     Make the fabricated forms ready.
    3.     Drill the holes on the marked locations on the forms ‟2‟ sides according to the
           attached sketch to receive inserts holding bolts.
    4.     Fix the column inserts plates assembly on the fabricated forms and the bolts
           fastened as per sketch.
    5.     Erect the forms, support, well secure and concrete pour be carried out.
    6.     Having the pour been over, before striking the forms, the threaded bolts be taken
           out.
    7.     Later the holes left shall be filled with Galvanised threaded rod 15mm long.
Equipment
Fabricated Plates with Threaded holes, Pins and Bolts.
Attachment
Sketches
#19

Excavation for
132kv
cable interconnection
Top

Comments incorporated
Duct bank construction added
Index
Scope
Reference documents
Definitions
Responsibilities
Safety

Method
Equipment
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              45 of



Attachment
Scope
This statement is aimed to present the proposed procedures to be adopted to carry out the
excavation in preparation for laying of the 132 KV electric cable from the GUP power station
through to the Company project site substation.
Reference documents
Specification , Excavation & Backfilling for Underground structures.
Definitions
PSM            Project Site Manager
CM             Construction Manager
CS             Construction Superintendant
FM             Foreman
Responsibilities
The CM shall plan and resource the trench excavation and backfilling activity, in accordance
with this method statement.
The CS shall control, coordinate and supervise all the activities directing the Construction
Foreman
The Construction Foreman shall practically execute these activities, direct the workforce as
necessary and report to the CS for all day to day operational matters.
EPC Contractor shall control all the activities.
Safety
Prior to the commencement of any activities, the labour force shall receive a tool box talk
every day on the project site safety requirements. Any process to be adopted having a
particular safety risk shall be assessed and addressed as required.
Method
Permits for the involved area excavation shall be obtained from the relevant authorities.
The surveyor shall set out the proposed route of the electric cable trench per IFC drawings.
Any existing services shown on these drawings or on the record drawings shall be located and
identified by an EPC Contractor approved method (i.e. catscan). Wherever necessary, trial pits
shall be manually excavated to expose the existing services.
Wherever, the protection of the existing services are required, adequate protection and
warning shall be installed. Cables or pipes that span the excavation shall be supported. Rigid
ducts and trays shall be provided to protect and support these cables. All existing services
encountered, shall be plotted by the surveyor on an as-built drawing.
The trench shall be excavated by a track excavator to the correct lines and levels. Wherever
necessary or as defined on the work permit, manual hand excavation shall be carried out.
The sides of the excavation shall be sloped. Barriers shall be placed to indicate an open
excavation.
The excavated material shall be stockpiled along the trench areas for re-use. Surplus material
shall be removed to the tip area by dump trucks. The surveyor shall monitor the lines and
levels of the excavation activity.

Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              46 of



Upon EPC Contractor inspection, the excavated trench shall be released for the next
operation as indicated upon the activity ITP following which, compaction of the formation level
be carried out to the specified density. The field compaction test report shall be submitted.
The surveyor shall provide suitable level pins that indicate the correct elevation of the sand
bedding required for the cables. The sand bedding shall be laid and compacted in accordance
with the specification. The cables shall be placed correctly within the trench in line with the
IFC drawings. Cables shall be laid by the electrical department upon completion of which,
EPC Contractor release the trench for the backfill and subsequent activities. Suitable approved
backfill material shall be placed in layers, compacted around the cable & field tested.
Cable tiles and warning tape shall be placed on top of the sand fill per approved drawing.
This backfill activity shall continue up to existing ground level & the site left tidy
For the construction of the duct banks, the duct pipes shall be laid according to the sectional
design details with fixing arrangements, forms erected to the required profiles. The concrete
shall be poured at various intermediate locations in the first instance to create temporary
downward anchor to counteract any possible duct uplift by the underducts fluid concrete
upward pressure. When the arrangement is completed, the whole section be concreted to the
defined level & finished accordingly.
Major Equipment
Cable Markers.
Excavation equipment.
Dump trucks.
Compactors.
Attachment
None
#20
Road crossing                                                  for                 132                kv route
       Top
Index
Scope
Reference documents
Definitions
Responsibilities
Safety
Method including traffic management scheme
Equipment
Attachment
Scope
The purpose of this method statement, is to define the sequence and methodology for the
excavation and laying of PVC ducts , that shall cross existing roads at locations identified on
the attached drawing part .
Reference documents
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              47 of



Specification. Excavation & Backfilling for Underground structures.
(INTERCONNECTS UNDERGROUND LAYOUT DRAWING SHEET „ 5 „)
Definitions
PSM            Project Site Manager.
CM             Construction Manager.
CS             Construction Superintendant
FM              Foreman
Responsibilities
CM shall plan and resource the trench excavation and backfilling activity, in accordance with
this method statement.
The Construction Foreman shall monitor these activities, directing the workforce as necessary.
EPC Contractor shall control the service laying activities.
Safety
Prior to the commencement of any activity, the labour force shall receive a tool box talk on the
project site safety requirements. Any process that is adopted having a particular safety risk
shall be assessed and addressed as required.
A competent inspector shall inspect the trench daily to assess the safety measures adopted
as well as after every rainstorm. If required , the shoring shall be provided to prevent the
caving in . In case of the trench depth being more than 1200 mm , adequate means of exit
such as ladder or steps shall be provided and located no more than 8 m of lateral travel.
Barricades , markers and the night lights etc., shall be arranged as required.
Method
The required permit to work shall be obtained from the Plant Refinery Division.
A traffic management scheme that has been presented herein as detailed on the attached
sketch for this road crossing which includes, reduced speed sign, temporary diverted roads
sign, men at work sign, warning signs, informatory signs, safety barriers,night lighting and road
cleaning activities shall be implemented on site after review & approval by EPC Contractor
prior to commencing the work.The aforesaid traffic management scheme is described below
Traffic Scheme Road Crossing
Inter Connects Underground Layout Drg
This proposed crossing is located on the road avenue C as shown on the attached sketch
This is a 2 way road with a central verge and carrying 2 lanes on either way
The road shall be divided in 2 parts as shown on the sketch as lane L1 and L 2 on either
side of the carriage way
In the first instance the work shall be carried out on part L1 diverting the traffic to the road
portion on the part L2 as shown on the sketch
In the second instance the work shall be carried out on part L2 diverting the traffic to the road
portion on the completed road portion on the part L1 as shown on the sketch
The first reduce speed for traffic diversion informatory board depicting shall be located at 300
m from the point of the proposed crossing, the second depicting diversion sign be located at
200 m and the third depicting men at work sign be located at 100 m on either way in the
opposite directions.

Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              48 of



The first section of road crossing as per the attached sketch shall be marked by the surveyor
on the actual road location. Any existing services shall be identified and protected.
The asphalt shall be cut using a mechanical cutter machine.
The road section shall be excavated to the correct level using mechanical means and removed
from the site to stock pile area.
The excavated material shall be removed to a stockpile area.
Appropriate bedding material shall be placed within the excavated trench to the correct service
level. Wherever required, this bedding shall be compacted and tested for field density.
The cable ducts or service pipes shall be laid at the required levels and profile according to the
drawings as well as the specifications and approved by the EPC Contractor‟s Engineer.
Backfill around the service pipes shall be carried out with the appropriate approved material.
This service pipe surround material shall be compacted complying with the project
specifications. Test results shall be reported.
General fill up to the underside of road formation shall be placed in 150mm layers compacted
mechanically complying with the specifications.
A concrete slab shall be cast up to the bottom of the finished asphalt level and the finishing
done by using approved asphalt mix .
The traffic management system shall be removed after the road crossing has been cleaned of
any debris or obstructions.
Either side of the road shall be provided with cable markers to indicate the services
Equipment
Excavator .
Dump trucks.
Compactors.
Attachment
Sketch showing the traffic diversion.
Sketch showing the location of the proposed crossing.

#21
Night shift working - earthworks
Top
Index
Scope
Reference documents
Definitions
Responsibilities
Safety
Method
Equipment
Attachment

Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              49 of




Scope
The purpose of this method statement, is to define the procedure that shall be adopted for the
earthworks activity during Night Shift.
Reference documents
Specification
Definitions
EPC Contractor
Civil Contractor
IS      Infrastructure Superintendent.
PSM Project Site Manager
SO     Safety Officer
Responsibilities
The PSM shall ensure that adequate site management and supervision is available for night
shift working.
A dedicated SO shall patrol the site during the night shift activities, and where necessary,
stopping the work if an unsafe situation arises.
The necessary work permits shall be obtained prior to the start of the night shift activities.
Safety
The SO shall ensure all those persons who shall work on the night shift activities, are fully
aware of the safety obligations expected from them. The emergency procedure for first aid
shall be explained to every body. (Refer to the safety plan for night shift working).
All equipment that shall operate on the site shall be in full working order with appropriate
lighting.
Method
The activities that are schedules to be carried out during night shift comprise of excavation,
hauling, stockpiling, spreading, leveling, watering and compaction. These activities do not
require any specific QC inspection coverage other than the supervisor surveillance.
The IS shall prepare the schedule define the work faces of the night shift activity prior to
beginning.
The work faces shall be illuminated by using tower-mounted easily repositionable floodlights.
The routes which the construction equipment shall use for hauling „the excavated materia‟,
shall be made safe prior to work commencing.
The area for stockpiling the material shall also be illuminated.
A banksman wearing a high visibility vest shall direct the stockpile area. Similarly, a banksman
shall direct the excavation area. The two banksmen shall be in communication with each other
by two way communication facilities (mobile phones).
The earthwork supervisor and the SO shall patrol the entire site overseeing all activities.
Emergency Procedure.
The Safety Officer shall be responsible for coordinating the night shift emergency procedure.
Upon an emergency arising, the Safety Officer shall be notified.
The Safety Officer shall immediately alert the relevant emergency services if so required.
997 for Fire or civil defence
998 for an Ambulance.
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              50 of



999 for Police.
The Safety Officer shall notify the Safety Manager of the emergency occurence. Should the
camp doctor be required, he shall be notified. The Safety Manager shall attend the emergency
and take control of the situation.
The required notification, investigation and reporting of the emergency shall be conducted in
accordance with the site HSE plan.
First Aid.
First aid facilities shall be made available for night shift operations at the camp clinic.
The Safety Officer shall have the telephone number of the camp doctor who be summoned in
the event of first aid requirements and emergencies.
Equipment
Excavators.
Dump trucks.
Attachment
None.

(Revised)
Additional manufacturer‟s instructions for mixing incorporated
Form details amended
Manufacturer‟s method statement attached
#22
Grouting to pipe rack foundation bases
Top
Index
Scope
Reference documents
Definitions
Responsibilities
Safety
Method
Equipment
Scope
The purpose of this Method Statement is to grout the annular space between the foundation
top and the structural steel base plates.
Reference Documents
Specification
Definitions
PSM                      Project Site Manager
CM                       Construction Manager.
CS                       Construction Superintendent .
FM                       Foreman.
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              51 of




Responsibilities
The CM shall plan and resource the Cementitious grout activities, to ensure that they are
implemented according to this procedure, with the correct equipment resources.
The CS shall ensure that all safety requirements are implemented and explained to the
erection workforce. The CS shall control the day to day activities
The FM shall control the workforce ensuring the full implementation of this method statement
including all safety measures.
Safety
Prior to the commencement of any activity, the suitably qualified labour force shall receive a
Toolbox Talk on the Project Site Safety Requirements. Any process that is adopted that may
have a particular Safety risk, shall be assessed and addressed as required.
About the Chemical effect, Masks to be worn, Safety glasses and gloves to be used
Areas of Activity to be Barriered Off / No Unauthorized Entry,
Sufficient Lighting to be provided where necessary.
Method
The surface to be grouted shall be chipped          / scabbled without using mechanical bush
hammer to expose the aggregate and remove the laitance. The finished surface shall be free
from oil, dust , dirt, paint, curing compounds etc and be soaked in with water for 24 hours prior
to grouting to minimize the localized absorption as well as to assist the free flow of the grout.
The bolt holes / pockets shall be waterfree prior to placement of grout.
The baseplates / bolts shall be clean and free of oil, grease and paint and correctly aligned
according to the approved drawings.
The stainless steel shims 50x50x10 mm thick shall be in correct locations covered with mortar
so as to allow at least 50 mm grout cover on shim sides.
The forms as shown on the attached sketch shall be erected on the defined locations provided
with chamfers.
An electric drill fitted with a paddle shall be used for the grout mixing purpose using water @
3.5 to 4.5 litres per 25 kg bag of Master flow 928 according to product datasheet.
The mixer shall be clean with no standing water.
Let 90 % of the applicable quantity of water required to achieve the desired consistency to
meet the batch volume per manufacturer‟s datasheet be added to the mixer before adding the
grout and the Masterflow be added gradually while simultaneously, pouring in to the mixer the
remaining 10 % water quantity during mixing which has to be kept on for at least 3 to 5 minutes
until a uniform lump free consistency is achieved.
The grout shall be poured continuously using the grout pour cone with a constant hydrostatic
head of at least 15 cm
Having poured the grout Masterflow 928 in place, cover all exposed grout material with clean
damp Hessian and be kept moist until grout is firm enough to accept a curing membrane
The temperature range 4 to 32 degree C shall be maintained for the 3 post pour continuous
days.
The grout thickness varies between 25 to 50 mm.
Equipment
Peddle Mixer
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              52 of



Grout Flow Cone
Attachment
Sketch
Masterflow Catalogue
Masterflow Method Statement

#23

Cementitious grouting to foundation
bases
Top
Index
Scope
Reference documents
Safety
Method
Equipment
Scope
This statement is aimed to propose the procedures to be adopted to grout the base plates of
the stationary equipment / vessels foundation bases.
Reference Documents
Specification
Safety
Prior to commencement of any activity, the labour force shall receive a STARRT
Card      /   Toolbox Talk relevant to the operation concerned on the project site safety
requirements. Necessary measures shall be applied to any process involving a safety risk
Safety Supervision
A competent inspector shall visit the area daily to assess the safety measures adopted. Any
snag observed during his visit shall be notified to the supervisor present who immediately act
to bring the safety measures to an acceptable standard
Method
The surface to be grouted shall be chipped / scabbled without using mechanical bush
hammer to expose the aggregate and remove the laitance.
The finished surface shall be free from oil, dust , dirt, paint, curing compounds etc and soaked
with water for 24 hours prior to grouting to minimize the localized absorption as well as to
assist the free flow of the grout.
The pockets shall be waterfree prior to placement of grout.
The baseplates shall be clean and free of oil, grease and paint and correctly aligned in line
with the approved drawings.

Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              53 of



The stainless steel shims 50x50x10 mm thick shall be in correct locations covered with mortar
so as to allow at least 50 mm grout cover on shim sides.
The forms as shown on the attached sketch shall be erected on the required locations with
chamfers.
An electric drill fitted with a paddle shall be used for the grout mixing purpose using water @
3.5 to 4.5 litres per 25 kg bag of Master flow 928 according to requirement.
The mixer shall be clean with no standing water.
Let 90 % of the measured quantity of water required to achieve the desired consistency
according to the batch volume be added to the mixer before adding the grout and the
Masterflow be added gradually ,simultaneously pouring in the remaining 10 % water quantity
during mixing , which has to be kept on for at least 3 to 5 minutes until a uniform lump free
consistency is achieved.
Let the grout be poured continuously using the grout pour cone with a constant hydrostatic
head of at least 15 cm
Having poured the grout Masterflow 928 in place , cover all exposed grout with clean
dampen Hessian and be kept moist until grout is firm enough to accept a curing membrane
The temperature range 4 to 32 degree C shall be maintained for the 3 post pour continuous
days
The grout thickness varies between 25 to 50 mm.
Major Equipment
Peddle Mixer
Grout Flow Cone
Attachment
Sketch
Masterflow Catalogue
Masterflow Method Statement
#24
Etylene compressor
Massive foundation (concrete pour)
Top
Index
Scope
Reference Documents
Definition
Responsibilities
Safety
Method
Attachment
Scope

Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              54 of



The purpose of this method statement is to define the sequence and methodology that shall be
implemented for the Concrete pour of the Ethylene Compressor Foundation.
Documents
Specification
Drawing No:
Definitions
CM             Construction Manager
CS             Construction Superintendent
FM             Foreman
Responsibilities
CM shall plan and resource the required materials ensuring that these are implemented
according to this procedure.
CM shall ensure that all the Safety requirements are implemented and explained to the
relevant work force and control the day to day activities.
CS shall ensure the implementation of technicalities involved.
FM shall control the work force ensuring the full implementation of the procedure.
Safety
Prior to the commencement of any activites, the labour force shall receive a toolbox talk on the
Project Site Safety requirements. Any process that is adopted that may have a particular
Safety risk, shall be assessed as required.
Method
    1.     Pour Size = (14.86 x 11.24 – 2.56 x 0.84) 1.7 = 280.2892 approximately
    2.     Pour Plan = In Strips Courses of each 11.24m x 2m x 0.4m i.e. width wise (8.992
           each).
    3.     Sequence of strips shown in attached details in numbers.
    4.     Time of Pour commencement 7.30 / 8.00 Hrs.
    5.     Plants - Concrete Pumps 1No.
               Batching Plant 1No. Full Time. / Stand by 1No.
               Transit mixer 7 Nos. 7m³ each
               Delivery continuous @ 7minutes intervals.
    6.     Pour Duration 6 to 7 hrs.
    7.     Equipment:
            Vibrator – Pneumatic / Diesel Operated 3 Nos. (2Nos.in use and 1 Stand by)
               and 3 Nos. on other sites.
    8.     Curing-Thermal
            Immediate Post Pour: By Curing Compound covered by Polythene membrane.
            Post Pour Set concrete: By removing Polythene, adding saturated Hessian,
               recovering with Polythene membrane and filling clean sand 150mm except the
               column portion which shall be surrounded by small sand embarkments. The sand
               shall be kept sprayed with water.
    9.     Water Supply: By tank, full tank ready on site with 50m water hose pipe.
    10.    Manpower:
        Concrete Crew
                      Foreman      - 1 No.
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              55 of



                            Steel fixers – 2 Nos.
                            Carpenters – 2 Nos.
                            Masons        - 12 Nos.
                            Helper        - 12 Nos.
      11.          Specifications
                   High Slag blast furnace cement to BS 4246 with 70% replacement utilising 30%
                   ASTM C150 Type II cement for use in massive concrete.
      12.          Concrete Temperature 30°C.
                   Slump 150 – 175mm

Attachment
1 Sketches
2 Plan of Pour
3 Sectional Sequence details of pour layers.

#25
Propane compressor
Massive foundation (concrete pour)
Top
Index
Scope
Reference Documents
Definition
Responsibilities
Safety
Method
Attachment
Scope
The purpose of this method statement is to define the sequence and methodology that shall be
implemented for the Concrete pour of the Ethylene Compressor Foundation.
Documents
Specification
Drawing No:
Definitions
PSM           Project Site Manager
CM            Construction Manager
CS            Construction Superintendent
FM            Foreman
Responsibilities
CM shall plan and resource the required materials ensuring that these are implemented
according to this procedure.
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              56 of



CM shall ensure that all the Safety requirements are implemented and explained to the
relevant work force and control the day to day activities.
CS shall ensure the implementation of technicalities involved.
FM shall control the work force ensuring the full implementation of the procedure.

Safety
Prior to the commencement of any activites, the labour force shall receive a toolbox talk on the
Project Site Safety requirements. Any process that is adopted that may have a particular
Safety risk, shall be assessed as required.
Method:
    1 Pour Size = (12.0 x 7.5 – 2 x 0.44 x 0.78) 1.7 = 151.833 approximately
    2 Pour Plan = In Strips Courses of each 7.5 x 2 x 0.4m i.e. width wise (6.0m³ each).
    3 Sequence of strips shown in attached details in numbers.
    4 Time of Pour commencement 7.30 / 8.00 Hrs.
    5 Plants - Concrete Pumps 1No.
               Batching Plant 1No. Full Time. / Stand by 1No.
               Transit mixer 7 Nos. 7m³ each
               Delivery continuous @ 7minutes intervals.
    6 Pour Duration 5 to 6 hrs.
    7 Equipment:
           a. Vibrator – Pneumatic / Diesel Operated 3 Nos. (2Nos.in use and 1 Stand by)
               and 3 Nos. on other sites.
    8 Curing-Thermal
           a. Immediate Post Pour: By Curing Compound covered by Polythene membrane.
           b. Post Pour Set concrete: By removing Polythene, adding saturated Hessian,
               recovering with Polythene membrane and filling clean sand 150mm except the
               column portion which shall be surrounded by small sand embarkments. The sand
               shall be kept sprayed with water.
    9 Water Supply: By tank, full tank ready on site with 50m water hose pipe.
    10 Manpower:
        Concrete Crew
                    i. Foreman        - 1 No.
                   ii. Steel fixers – 2 Nos.
                  iii. Carpenters – 2 Nos.
                  iv. Masons          - 12 Nos.
                   v. Helper - 12 Nos.
    11 Specifications
    12 High Slag blast furnace cement to BS 4246 with 70% replacement utilising 30% ASTM
        C150 Type II cement for use in massive concrete.
    13 Concrete Temperature 30°C.
           Slump 150 – 175mm
Attachment
1 Sketches
2 Plan of Pour
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              57 of



3 Sectional Sequence details of pour layers.

      #26
SeaWater Basin
Baffle Walls (concrete pour)
Top
Index
Scope
Reference Documents
Definition
Responsibilities
Safety
Method
Attachment
Scope
For pouring the baffle walls 9 #s located on the deeper end slope of section AA between the
PCJ and the commencement of the falls as the width of the slope being 5.35m.
Since no provision of the starter rebars has been made for the slope portion at the „slab base
level‟ for the baffle walls to be connected with then to ensure the structural stability, we
propose the following operational descriptions for the construction execution of these
elements.
Documents
Drawing No:
Definitions
PSM            Project Site Manager
CM             Construction Manager
CS             Construction Superintendent
FM             Foreman
Responsibilities
CM shall plan and resource the required materials ensuring that these are implemented
according to this procedure.
CM shall ensure that all the Safety requirements are implemented and explained to the
relevant work force and control the day to day activities.
CS shall ensure the implementation of technicalities involved.
FM shall control the work force ensuring the full implementation of the procedure.
Safety
Prior to the commencement of any activites, the labour force shall receive a toolbox talk on the
Project Site Safety requirements. Any process that is adopted that may have a particular
Safety risk, shall be assessed as required.
Method

Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              58 of



Stage 1:                 Pouring the walls in full heights between the wall designated „M‟ and the
                         construction joints locations.
Stage 2:                 Pouring the portion of the baffle walls between the construction joint and the wall
                         end upto a level of 7.14m from the slab base.
Stage 3:                 Pouring the remaining portion of the baffle walls from the level 7.14 upto the level
                         13.5 with a simple construction joint at the level of 7.14m.
Attachment
None.
#27
SeaWater Basin
Minor Concrete Repair at Kicker Face

Top

Index
Scope
Definition
Responsibilities
Safety
Equipment
Material
Method
Attachment
Scope
For minor concrete repair specially at kicker face Filling of Tie rod holes.
Reformation of grooves for sealant on floor slabs and walls.
Definitions
PSM            Project Site Manager
CM             Construction Manager
CS             Construction Superintendent
FM             Foreman
Responsibilities
CM shall plan and resource the required materials ensuring that these are implemented
according to this procedure.
CM shall ensure that all the Safety requirements are implemented and explained to the
relevant work force and control the day to day activities.
CS shall ensure the implementation of technicalities involved.
FM shall control the work force ensuring the full implementation of the procedure.
Safety
Prior to the commencement of any activites, the labour force shall receive a toolbox talk on the
Project Site Safety requirements. Any process that is adopted that may have a particular
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              59 of



Safety risk, shall be assessed as required. Use of safety glasses, gloves, mask, etc., shall be
made.
Equipment
ROADCRAFT model #. 5615 NEEDLE Scaler (Light version for removal of rust, welding slag,
old paint etc.)
Material
Material Epoxy bonding agent MBT Concresive 1414 (permanent epoxy adhesive for internal
or external bonding for renderings, concrete repairs, bonding concrete to concrete, steel and
granolithic toppings)
MBT Masterflow 544 (High strength, non shrink cementitious mortar ready to use product in
powder form requiring only on site addition of water to produce a non–shrink mortar of
predictable performance formulated for use at plastic consistency for bedding, repairing,
grouting and void filling such as concrete repairs, void filling between old and new concrete,
filling tie bar holes etc.)
Method
1 The existing surface shall be scabbled, all loose concrete and mortar drippings removed
      by using a single head scabbler and / or RODCRAFT model # 5615 NEEDLE scaler.
2 Epoxy bonding agent MBT Concresive 1414 shall be applied by brush and allowed to cure.
3 MBT Master flow 544 shall be mixed with water in small pails by hand complying with
       manufacturer‟s data sheet and trowelled onto the surface.
4. Approved curing compound shall be applied immediately
5 A wooden strip 25mm wide X 20 mm deep shall be placed at the centre of the joint on the
      existing rebates in the floor slabs as well as walls and the space on either side be filled
      with MBT Master flow 544 to obtain a clear rebate of X-size 25mm x 20 mm followed by
      removal of the wooden strip within an hour of fill and the reformed surfaces be sprayed
      with approved curing compound.
Attachment
Manufacturers Catalogue
#28
Seawater basin
   (water tightness BS 8007: 1987)
Top
Index
Scope
Definition
Responsibilities
Safety
Method / Procedures
Equipment
Attachment
Scope
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
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To transport the Sea Water to the Sea Water Basin and Testing the basin
Definitions
PSM             Project Site Manager
CM              Construction Manager
CS              Construction Superintendent
FM              Foreman
Responsibilities
CM shall plan and resource the required materials and plants ensuring that these are
implemented according to this procedure.
CM shall ensure that all the Safety requirements are implemented and explained to the
relevant work force and control the day to day activities.
CS shall ensure the implementation of technicalities involved.
FM shall control the work force ensuring the full implementation of the procedure.
Safety
Prior to the commencement of any activites, the labour force shall receive a toolbox talk on
the Project Site Safety requirements. Traffic directory signs for the ramp breakers on 3
nos road crossings shall be installed. On the exposed pipe route the safety tags shall be
installed with cones. A protection arrangement shall be made for the plants at the
intake. A full time attendant shall keep the watch and ward on the route.
Procedures involved
Laying a 100 mm dia hose from the sea to the sea water approximately1800 m. Refer to
sketch point # 1 to # 8 i.e. intake at sea and discharge to the basin respectively.
Constructing a concrete anchor at the sea to fix the intake pipe spout horizontally and
vertically as well as to fix 2 # heavy duty centrifugal pumps at point #1
There are 3 nos road crossings en-route at points 2, 5 and 6 on which temporary 150 mm
dia pipe sleeves are to be inserted in the form of the ramped speed breakers.Ref to the
sketch. Otherwise, sleeves shall be inserted by road cutting, filling and making good when
the job is over
Install a „round the clock‟ generator to supply electricity to the pumps with the Distribution
Board at point # 1 or to have electric connection through an alternative source.
Install a timber clamping platform on the ditch at point # 4
Water Heads calculations indicative only
At intake suction                    1m
At intake disposal                    1m
Vertical head loss                   25 m
At point Nos. 8 loss                 10 m
Total vertical head loss             37 m
Length of Pipe for friction loss 1800 m 4 f l v v / 2 g d
= 4x.015x1800x1.5x1.5 / 2x 9.81x.1=123.9m
Total head loss = static loss + dynamic loss = 37 +123.9 = 160.90 m
Work done= 42000x160.9 kgm, bhp = 42000x160.9 / 270000= 25 units, ihp = 35 units
The water flow velocity has been assumed to be 1.5 m / sec giving a discharge of 42 cum
per hour. It shall take 20 days to reach 20000 cum of water to the basin keeping round the
clock pumping.
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
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                                                                                                                                              61 of




                 SEA WATER BASIN PLANNED PUMPING
                 DAY #               QTYPUMPED                  QTY
                                     IN                         CUMM
                                     CUM                        CUM
                 1                   1008                       1008
                 2                   1008                       2016
                 3                   1008                       3024
                 4                   1008                       4032
                 5                   1008                       5040
                 6                   1008                       6048
                 7                   1008                       7056
                 8                   1008                       8064
                 9                   1008                       9072
                 10                  1008                       10080
                 11                  1008                       11088
                 12                  1008                       12096
                 13                  1008                       13104
                 14                  1008                       14112
                 15                  1008                       15120
                 16                  1008                       16128
                 17                  1008                       17136
                 18                  1008                       18144
                 19                  1008                       19152
                 20                  1008                       20160
                 21                  1008                       21168
First phase Testing
The tank completed with Protective Coatings as specified and sealant applied shall be
cleaned and filled to the normal maximum level to meet the requirement of clause 9.2
BS 8007 : 1987 Testing of structures i.e. upto 11.5 m which should take 14 days and
then be retained for a stabilising period of 7 days for a maximum design crack width of
0.1 mm, allowing absorption and the autogenous healing.
Test period starts now for 7 days and the drop in level recording be made every 24 hours
during this 7 days period. Total permissible drop in level allowing evaporation etc. should
not be more than 1 / 500 of the average water depth of the full tank which limits to 10
mm or another specified or calculated amount.
Having the test been successful, the backfill shall be carried out
Second phase Testing
Let the tank be further filled upto 13 m level i.e another 7 days
Stabilisation period Another 7 days (for absorption and autogeneous healing)
Test period Another 7 days (level drop recording at an interval of 24 hours)
Basin Filling and Testing Schedule
        S
       Description of the operation           Duration in             Remark
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
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           #                                                                        days
           1
         Ist phase water pumping                                                                14                     Pumping from sea
           2
         Retained water stabilisation to                                                        7
         allow       absorption       and
         autogeneous healing
           3
         Testing at 24 hour intervals and                                                       7                      Loss should not be more
         monitoring                                                                                                    than 1 / 500 of average
                                                                                                                       fullwater depth or 10 mm
                                                                                                                       or other specified value
                                                                                                                       but excluding evaporation.
           4
         Backfilling                  after         successful                                  14
         testing

            phase water pumping
         II 5                                                                                   7                      Pumping from sea

          6
         Retained     water stabilisation                                                       7
         and autogeneus healing
          7
         Testing at 24 hours intervals                                                          7

          8
         Water loss monitoring                                                                                         Loss should not be more
                                                                                                                       than 1 / 500 of average
                                                                                                                       fullwater depth or 10 mm
                                                                                                                       or other specified value
                                                                                                                       but excluding evaporation


The code provides that notwithstanding the satisfactory completion of the test, any
evidence of seepage of the liquid to the outside faces of the liquid retaining walls should
be assessed against the requirement of the specification. Any necessary remedial
treatment of the concrete, cracks or joints should, where practicable, be carried out from
the liquid face. When a remedial lining is applied to inhibit leakage at a crack, it should
have adequate flexibility and have no reaction with the stored liquid.
Should the structure not satisfy the 7 days test then after the completion of the remedial
work, it should be refilled and if necessary, left for a further stabilising period followed by a
further test of 7 days’ duration should then be undertaken in accordance with this clause.

Equipment.
Pumps IHP 35,      2 Nos.
Other General Arrangements
Attachment
Sketch showing the Hose Route
#29
Road Crossing for 132 kV route
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              63 of




             Top
Index
Scope
Reference documents
Definitions
Responsibilities
Safety
Method including traffic management scheme
Equipment
Attachment

Scope
The purpose of this method statement, is to define the sequence and methodology for the
excavation and laying of PVC ducts, that shall cross existing roads at locations identified on
the attached drawing part.
Reference documents
Specification. Excavation & Backfilling for Underground structures.
Drawing No. (INTERCONNECTS UNDERGROUND LAYOUT „)
 Definitions
PSM           Project Site Manager.
CM            Construction Manager.
CS            Construction Superintendant
FM            Foreman
Responsibilities
CM shall plan and resource the trench excavation and backfilling activity, in accordance with
this method statement.
The Construction Foreman shall monitor these activities, directing the workforce as necessary.
EPC Contractor shall control the service laying activities.
Safety
Prior to the commencement of any activity, the labour force shall receive a tool box talk on the
project site safety requirements. Any process that is adopted having a particular safety risk
shall be assessed and addressed as required.
A competent inspector shall inspect the trench daily to assess the safety measures adopted as
well as after every rainstorm. If required, the shoring shall be provided to prevent the caving
in. In case of the trench depth being more than 1200 mm, adequate means of exit such as
ladder or steps shall be provided and located no more than 8 m of lateral travel. Barricades,
markers and the night-lights etc., shall be arranged as required.
Method
The required permit to work shall be obtained from the Plant Refinery Division.



Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
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A traffic management scheme which includes, reduced speed sign, temporary diverted roads
sign, men at work sign, warning signs, informatory signs, safety barriers, night lighting and
road cleaning activities
has been presented herein that shall be produced on site as detailed on the attached sketch
for this road crossing.
The traffic management scheme shall be reviewed and approved by EPC Contractor prior to
commencing the work.
The aforesaid traffic management scheme shall be implemented as described below:
Traffic Scheme Road Crossing
Drawing reference
Inter Connects Underground Layout
This proposed crossing is located on the road avenue C as shown on the attached sketch.
This is a 2 way road with a central verge and carrying 2 lanes on either way
The road shall be divided in 2 parts as shown on the sketch as lane L1 and L 2 on either side
of the carriage way.
In the first instance the work shall be carried out on part L1 diverting the traffic to the road
portion on the part L2 as shown on the sketch.
In the second instance the work shall be carried out on part L2 diverting the traffic to the road
portion on the completed road portion on the part L1 as shown on the sketch.
The first reduce speed for traffic diversion informatory board depicting shall be located at 300
m from the point of the proposed crossing, the second depicting diversion signs be located at
200 m and the third depicting men at work sign be located at 100 m on either way in the
opposite directions.
The first section of road crossing as per the attached sketch shall be marked by the surveyor
on the actual road location. Any existing services shall be identified and protected.
The asphalt shall be cut using a mechanical cutter machine.
The road section shall be excavated to the correct level using mechanical means and the
excavated material removed from the site to stock pile area.
Appropriate bedding material shall be placed within the excavated trench to the correct service
level. Where required, this bedding shall be compacted and tested.
The cable ducts or pipes service shall be laid at the required levels and profile complying with
the drawings, the specifications and approved by the EPC Contractor Engineer.
Backfill around the service shall be conducted using the appropriate material. This service
surround material shall be compacted as per the project specification requirements. Test
results shall be provided for the specification conformance verification.
General fill up to the underside of road formation shall be placed in 200mm layers and
compacted to 150mm using mechanical methods complying with the specification
requirements.
A concrete slab shall be cast up to the bottom of the finished asphalt level and the finishing
shall be done by using approved asphalt mix.
The traffic management system shall be removed after the road crossing has been cleared of
any debris or obstructions.
Either side of the road shall be provided with cable markers to indicate the services
Equipment
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              65 of



Excavator.
Dump trucks.
Compactors.
Attachment
Sketch showing the traffic diversion.
Sketch showing the location of the proposed crossing.
#30
Administration building
Stair landing extension at grid 4 j
Top


Index
Scope
Reference documents
Definitions
Responsibilities
Safety
Method including traffic management scheme
Equipment
Attachment
Scope
The aim of this statement is to define the methodology how the extension to the existing part
of the stair first flight landing at grid 4 J shall be effected to and connected to the existing RCC
column as well as the correction to the proposed rebars to be placed in the portion of the first
flight.
Reference documents

Definitions
PSM           Project Site Manager.
CM            Construction Manager.
CS            Construction Superintendant
FM            Foreman
Responsibilities
CM shall plan and resource the trench excavation and backfilling activity, in accordance with
this method statement.


The Construction Foreman shall monitor these activities, directing the workforce as necessary.
EPC Contractor shall control the service laying activities.

Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
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                                                                                                                                              66 of




Safety
Particular safety shall be taken to cover the drilling in concrete activity and the pouring in the
resin into the holes.
The person grinding the concrete, drilling and filling in wear safety glass, gloves, masks etc.
Method
The proposed method involves the following procedures:
Extend the RCC landing from its existing line to the outside face of the column at grid 4 J.
Provide a shear key at the connection as shown for the extension as well as at column face
Maintain the flight width 1450 mm as designed keeping the column face flush with the waist
line of the first flight.
Arrange the rebars in the manner to be placed within the above dimensions according to the
details on drawing no…...
To accomplish the above operations, preparatory works shall be carried out as usual for the
form fixing and reinforcement placement.
A ground cut for the shear key shall be provided in the middle 1/3 portion 25 mm deep for the
bondage according to the sketch shown on the revised drawing ……. which continue across
the column face also.
Hilti HIT - HY 150 resin anchor system shall be used to dowel in the rebars for the extension
portion into the existing RC landing using 16 T dia bars into 22 mm dia. drilled hole 240 mm
long according to the manufacturer‟s instructions (System already approved). Hilti drill machine
TE 75 with 22 mm dia drill bits and the Hilti pouring gun kit 2000 shall be used.
The dowels shall be approved by the EPC Contractor engineer.
The remaining procedures shall be the usual operations regarding the RCC.
Equipment
Grinder, Hilti drill TE 75, Drill bits 22 mm dia, Kit 2000,
Material HIT HY 150 In Cartridges according to the requirement.
Attachment
Extract of Drawing

#31
SeaWater Basin
Minor Concrete Repair at Kicker Face
   Top
Comments incorporated
Material already approved
Repairable depth shown on the sketch
Preparation & application modified
Curing method specified



Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
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                                                                                                                                              67 of



MINOR COMMENTS INCORPORATED
Index
Scope
Reference documents
Definitions
Responsibilities
Safety
Method
Equipment
Attachment
Scope
This statement is aimed to describe the procedures to be used to carry out making good the
existing concrete surfaces by rectifying the undulations formed during the slope pour
through cut outs on the top side slope shutters by the application of a shrinkage
compensated , high strength repair mortar reinforced with acrylic fibres on the broken and the
prepared surface.
The repairable thickness is only 10 mm.
Definitions
PSM            Project Site Manager
CM             Construction Manager
CS             Construction Superintendent
FM             Foreman
Responsibilities
CM shall plan and resource all the activities in accordance with this method statement.
The Construction Foreman shall monitor these activities, direct the workforce as necessary.
EPC Contractor shall control the activities.
Safety
The work personnel shall be given a Tool Box talk every day before the commencement of any
activity relevant to the operational requirements according to the Project Safety Needs.
In addition to the general safety measures to use personal safety Equipment,
all persons to work on the demolition breaker, and the proprietary products application shall
wear gloves, masks safety glasses etc
Equipment
Hilti Demolition Breaker TE 905 complete
Pointed mechanical chisel ( Bushing tool TP-SKHM 60 )
Material
EMACO S88C T in bags 25 kg each
Sodapcure WH curing compound
METHOD
A shrinkage compensated , high strength repair mortar reinforced with acrylic fibres
The area to be repaired shall be marked on site
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
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A depth of 10 mm from the proposed top level of concrete surface on the effected areas shall
be broken out to remove all substandard concrete using Hilti demolition breaker. The vertical
edges shall be cut with a grinder.
The substrata shall be prepared to a rough surface having at least 5-mm amplitude at 20-mm
frequency
The prepared surface shall be sound, dense, free of all oil, grease, loose and fractured
aggregate or other contaminants that could impair adhesion between the repair mortar and the
prepared concrete surface.
Thoroughly the repairable surface shall be wetted in to provide a „saturated surface dry
condition‟. Any standing water shall be removed prior to application of the mortar is
commenced
Priming of concrete
Prior to the application of EMACO S 88 CT , the concrete shall be wetted out with potable
water to give a saturated surface dry condition. No further bonding agent is required as per
manufacturer’s instructions.
TEMPERATURE CONDITIONS
EMACO S 88 CT shall be used when the ambient temperature is between +5 degree Celsius
and 50 degree C, otherwise chilled water be utilised to prevent the mix temperature exceeding
32 degree C
Substrata temperature should not be less than 5 degree C. In hot weather, areas to be
repaired shall be shaded to prevent from direct sunlight
MIXING
Hand mixing with trowel or similar of EMACO S 88 C T is not permitted according to the
manufacturer‟s instructions, therefore, a low speed electric drill with paddle attachment with a
forced action mixer shall be used.
Water addition shall be between 3.5 to 4 litres of potable water per 25-kg bag.
The required quantity of water shall be poured into the pre- wetted mixing drum, and mixer
started followed by the addition of EMACO S 88 C T powder rapidly and continuously,The
mixing shall continue for 3 to 4 minutes after all the powder has been added until the mortar is
homogeneous and lump free
More water shall be added within the limits given, if necessary,until the required consistency is
achieved and mixed for a further 1-minute.
APPLICATION
After mixing, EMACO S 88 C T , the material shall be trowel applied by forcing into the
prepared substrate ensuring intimate contact and good compaction
The surface of the placed mortar shall be levelled using a wooden float. Final finishing mat is
done with a steel trowel.
CURING
Curing shall be done by spraying the approved compound SODAPCURE WH
A polythene membrane shall be used to protect the finished surface from the wind blown sand.
Attachment
Manufacturer‟s method statement
Sketch showing section
#32
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              69 of




Fencing
Top
Index
Scope
Reference documents
Definitions
Responsibilities
Safety
Method
Equipment
Attachment
Scope
The purpose of this method statement, is to define the sequence and methodology for the
construction and erection of the site security fencing.
Reference documents
Specification
Standard Drawing
Standard Drawing
Site Fence Location drawing
Definitions
PSM            Project Site Manager.
CS             Construction Superintendent.
Responsibilities
The CS shall plan and resource the fencing activities, to ensure that they are constructed and
erected according to the specifications.
The Construction Foreman shall monitor the precasting and erection activities, directing the
workforce as necessary.
Safety
Prior to the commencement of any activities, the labour force shall receive a tool box talk on
the project site safety requirements. Any process that is adopted that may have a particular
safety risk, shall be assessed and addressed as required.
Method
Precast elements.
A precast yard shall be established as shown on the attached sketch. The casting beds shall
be such that pouring, stripping, curing and coating can be achieved easily. A casting cycle of 4
days is anticipated for casting, initial curing and coating, prior to removal to site.
Easily assembled and stripped steel prefabricated moulds shall be utilized for the fence
foundation and ground beam.
Fence erection.
The final grade level of the area shall be the commencement point for the fence construction.
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
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A level survey shall demonstrate the accuracy of the site grading activity.
The Survey Team shall set out the line and level of the fence, including post locations for all
elements.
Using a machine mounted auger, 300 and 450mm diameter holes as appropriate, shall be
drilled for the fence post foundations.
The drilled holes shall be cleaned and bedded to the correct base level.
The fence post foundation shall be placed in the drilled hole to the correct line and level.
Dune sand shall be compacted around the foundation.
The fence fabric shall be strung and tensioned as per the drawing details and manufacturers
recommendations attached items 1.14 through 1.21
Using hand tools, a trench shall be excavated for the ground beam.
The ground beam shall be placed to the correct line and level.
Suitable fill material shall be used to compact around the ground beam.
The fence fabric tie staple shall be grouted in position once the fence fabric is tensioned.
The gap between the ground beams, at the location of the fence post, shall be concreted to
form a continuous beam.
QC procedures shall be closed out on an on-going basis.
Equipment
Concrete Mixer truck.
Auger machine.
Wagon with hyab.
Plate compactor.
Attachment
Drwg no:
Drwg no:
Method statement for Link Middle East Ltd, Fence manufacturer.
#33

Administration building
Ceramic tiles flooring system
           Top

Index
Scope
Definitions
Responsibilities
Safety
Material
Method
Equipment


Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              71 of



Attachment
Scope
This statement is aimed to propose the procedures to be adopted to construct the
„ceramic tiles flooring system‟ which involves the laying of the bedding screed as well as the
finishing layer with grouting the joints including movement joints.
Reference documents
Drawing Nos.
Specifications
UBC & general construction practice
Definitions
PSM                      Project Site Manager
CSM                      Construction Manager
CS                       Construction Superintendent
FM                       Foreman
QC                       Quality Control
Responsibilities
PSM shall control the overall operations
CM shall arrange the resources required accordingly
CS shall control, monitor and direct the FM and workforce for the operations
FM shall execute the operations deploying the workforce
QC shall inspect all the operations according to the specifications
EPC Contractor shall conduct surveillance
Safety
The workers shall receive a Tool Box Talk according to the project requirement relevant to the
operation concerned every day prior to commencement of the activity
Proper illumination shall be provided in the dark area
The area to be tiled shall be closed for the general movement except those working there and
be opened only when the tiling has properly been completed with hardboard cover protection
spread on the newly laid flooring.
Materials
Ceramic floor tiles 300 x 300 x 10mm,
For General Area „RAK GP 21 G‟ and for wet areas Johnson „Athena‟
Joint filling grout – Approved proprietary material with matching shade.
Method
(Laying ceramic floor tiles by SEMI DRY method)
The areas of concrete sub strata to be tiled shall be brush cleaned and dampened until
absorption ceases followed by the finished floor level establishment by means of dots and
rules.
The total thickness of the ceramic tile flooring is 100 mm which includes 90 mm bedding
screed (1 cement: 4 mortar sand) by weight and shall be applied as described below.
The finishing layer shall be ceramic tiles 10 mm thick and be laid as described below.
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
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                                                                                                                                              72 of




The mortar for bedding the tiles shall be 1 part cement to 4 parts sand by weight, mixed semi
dry by a mechanical mixer with only sufficient water added to give a crumbly consistency which
retains its shape when squeezed by hand permitting no fluidity
The mix shall be placed to a thickness approximately 10 mm greater than that actually required
for the bed, thoroughly compacted by tamping and drawing off to the required level with a
screed board. Only sufficient mortar shall be mixed and spread as can be covered with tiles
before it attains its initial set.
Civil Contractor QC visual inspection shall be conducted
A slurry of 1 part cement to 1 part sand by volume shall be poured over the surface of the
semi – dry mix bedding and spread with a trowel until it is approximately 2 mm thick
Dry tiles shall then be laid on the slurry and beaten firmly into position with a wooden beater
ensuring a true surface contact between the tiles and bedding is formed.
The tiles shall be correctly positioned in both directions the time these are placed forming
joints using a proprietary tile spacer ( 1.5 mm for wall tiles and 3 mm for floor tiles)
The tiles shall neatly and accurately be cut to a close fit where necessary at abutments,
around outlets, pipes and the like.
Civil Contractor QC Inspection shall be conducted for the correct formation of joint alignment
and the level profile
The tiles shall be laid level or to 1- % falls in ‘wet’ areas as may be required. Localised
variations in level for a nominally flat floor shall be a maximum of +- 2-mm under a 3-meter
straight edge. Particular care shall be taken in ‘wet’ areas to prevent low spots that may
promote water pooling. The tolerance in the overall level shall not be more than 10 mm from
required finishes. (Reef STQ )
 Grouting of the joints shall be carried out within a period of not less than 24 hours after
completion of laying of tiles so as to allow the grout attach itself firmly to the bedding.
MOVEMENT JOINTS IN TILED FLOORS
Unless otherwise indicated in the documents, a 10 mm movement joint shall be formed at the
perimeter of all the tiled floors and where the tiling meets structural features such as columns,
machine bases etc.,
Where a structural movement joint is provided in the base, a movement joint of the same width
in the bedded finish shall be positioned immediately above
The movement joint cavities shall extend through the combined thickness of the finish and the
bedding mortar, completely filled and sealed after grouting of the normal joints takes place.
Major Equipment
Mechanical Mixer
Wheel barrows
Mason‟s tools in general
Attachment
None
#34

Administration building
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              73 of




Ceramic tiles flooring system
Top

Index
Scope
Definitions
Responsibilities
Safety
Material
Method
Equipment
Attachment
Scope
This statement is aimed to propose the procedures to be adopted to construct the
„ceramic tiles flooring system‟ which involves the laying of the bedding screed as well as the
finishing layer with grouting the joints including movement joints.
Reference documents
Drawing Nos.
Specifications
UBC & general construction practice
Definitions
PSM                      Project Site Manager
CSM                      Construction Manager
CS                       Construction Superintendent
FM                       Foreman
QC                       Quality Control
Responsibilities
PSM shall control the overall operations
CM shall arrange the resources required accordingly
CS shall control, monitor and direct the FM and workforce for the operations
FM shall execute the operations deploying the workforce
QC shall inspect all the operations according to the specifications
EPC Contractor shall conduct surveillance
Safety
The workers shall receive a Tool Box Talk according to the project requirement relevant to the
operation concerned every day prior to commencement of the activity
Proper illumination shall be provided in the dark area
The area to be tiled shall be closed for the general movement except those working there and
be opened only when the tiling has properly been completed with hardboard cover protection
spread on the newly laid flooring.
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              74 of




Materials
Ceramic floor tiles 300 x 300 x 10mm,
For General Area „RAK GP 21 G‟ and for wet areas Johnson „Athena‟
Joint filling grout – Approved proprietary material with matching shade.
Method
(Laying ceramic floor tiles by SEMI DRY method)
A continuous procedure to lay tiles over the cement mortar screed
The areas of concrete sub strata to be tiled shall be brush cleaned and dampened until
absorption ceases followed by the finished floor level establishment by means of dots and
rules.
The total thickness of the ceramic tile flooring is 100 mm which includes 90 mm bedding
screed (1 cement: 4 mortar sand) by weight and shall be applied as described below.
The finishing layer shall be ceramic tiles 10 mm thick and be laid as described below.
The mortar for bedding the tiles shall be 1 part cement to 4 parts sand by weight, mixed semi
dry by a mechanical mixer with only sufficient water added to give a crumbly consistency which
retains its shape when squeezed by hand permitting no fluidity
The mix shall be placed to a thickness approximately 10 mm greater than that actually required
for the bed, thoroughly compacted by tamping and drawing off to the required level with a
screed board. Only sufficient mortar shall be mixed and spread as can be covered with tiles
before it attains its initial set.
Civil Contractor QC visual inspection shall be conducted
A slurry of 1 part cement to 1 part sand by volume shall be poured over the surface of the
semi – dry mix bedding and spread with a trowel until it is approximately 2 mm thick
Dry tiles shall then be laid on the slurry and beaten firmly into position with a wooden beater
ensuring a true surface contact between the tiles and bedding is formed.
The tiles shall be correctly positioned in both directions the time these are placed forming
joints using a proprietary tile spacer ( 1.5 mm for wall tiles and 3 mm for floor tiles)
The tiles shall neatly and accurately be cut to a close fit where necessary at abutments,
around outlets, pipes and the like.
Civil Contractor QC Inspection shall be conducted for the correct formation of joint alignment
and the level profile
The tiles shall be laid level or to 1- % falls in ‘wet’ areas as may be required. Localised
variations in level for a nominally flat floor shall be a maximum of +- 2-mm under a 3-meter
straight edge. Particular care shall be taken in ‘wet’ areas to prevent low spots that may
promote water pooling. The tolerance in the overall level shall not be more than 10 mm from
required finishes. (Reef STQ Q)
Grouting of the joints shall be carried out within a period of not less than 24 hours after
completion of laying of tiles so as to allow the grout attach itself firmly to the bedding.
Movement joints in tiled floors
Unless otherwise indicated in the documents, a 10 mm movement joint shall be formed at the
perimeter of all the tiled floors and where the tiling meets structural features such as columns,
machine bases etc.,

Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              75 of



Where a structural movement joint is provided in the base, a movement joint of the same width
in the bedded finish shall be positioned immediately above
The movement joint cavities shall extend through the combined thickness of the finish and the
bedding mortar, completely filled and sealed after grouting of the normal joints takes place.
Major Equipment
Mechanical Mixer
Wheel barrows
Mason‟s tools in general
Attachment
None
#35

Administration building
Plastering and rendering
Top

Index
Scope
Definitions
Responsibilities
Safety
Material
Method
Equipment
Attachment

Scope
This statement is aimed to present the proposed procedures to be implemented for
carrying out the plastering and rendering operations. The term „plastering‟ herein is meant for
the internal surfaces while „rendering‟ for the external.
Reference documents
Drawing Nos.
Project specifications Nos. (For Sand) BS Code 1199, Table 1, (for Hydrated Lime) BS Code
890 Class B, (for cement) ASTM C150, (for galvanized metal lath, stops and beads) BS 1369,
(for preparation and application) UBC
Definitions
PSM           Project Site Manager.
CM            Construction Manager.
CS            Construction Superintendant
FM            Foreman
Responsibilities
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              76 of



CM shall plan and organise the Plastering and Rendering works in accordance with this
Method Statement.
The Construction Foreman shall monitor these activities, directing the workforce as per Site
requirements.
Safety
Prior to the commencement of work, the labour force shall receive the tool box talk on the
Project Site Safety requirements. Any process that is adopted which may have a particular
Safety risk, shall be assessed as required as per Site conditions and shall be taken care of. In
addition to that proper mason‟s scaffolding arrangements shall be made for providing access
to the required heights adopting all relevant safety measures.
Method
Preparation of backgrounds to be plastered or rendered
All surfaces to be plastered and rendered shall be thoroughly cleaned of all dust and loose
particles.
Concrete surfaces shall be scabbled by mechanical means to remove all laitance exposing the
aggregates to 3 mm depth
Civil Contractor / EPC Contractor inspections shall be conducted for the approval of the
prepared surfaces.
A slurry coat consisting of 400 kg Cement (white) to 1 cum of sand (No. 1 White Silica) as
specified shall be applied on the surface by trowel and 1-day allowance given for the
succeeding coat to commence with.
Block work surfaces shall have the joints raked out as specified (Ref) during construction.
Junctions of different background and the chases for the electrical conduits as well as other
service pipes shall be treated by fixing 200mm wide metal lath. Plastering shall not commence
until all the mechanical and electrical services, conduits, pipes and Ist stage fixtures have been
installed and approved.
Where a rendering or plaster is to be continuous across backgrounds of different types, a strip
of metal lath minimum 300 mm wide with an isolating membrane of polythene sheet or building
paper behind, shall be fixed across the junction. Where small widths of one material less than
300 mm wide are involved e.g. a concrete column, beam or slab dividing block panels, the
width shall be bridged completely for a distance of 150 mm on both sides.
The metal lath shall be stretched out and fixed along each edge at 100 mm centres using
stainless steel fasteners such as washers and shot fired pins, nails or screws and lapped joints
tied with galvanized wire, the screws fixed into plugs in predrilled holes if so required.
Metal lath shall not be provided where drawing shows a groove in the rendering or the plaster.
Fixing beads and stops
Beads, stops and the like shall be fixed plumb, square and true to line with clout nails or
plaster dabs at not more than 600 mm centres to each mesh wing.
Corner / angle beads at all openings as well as plaster ground stops at terminals shall be
installed by using stainless steel fasteners. Profile dots shall be formed on the surfaces.
Civil Contractor / EPC Contractor inspection shall be conducted for the proposed profile
approval.
Preparation of mixes for plastering or rendering
Slurry coat
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              77 of



400 kg cement: 1 cum sand
Second and third coats
300 kg cement: 50 kg lime: 1 cum sand
Plaster thickness
19 mm walls and 14 mm ceilings
The hydrated lime shall first be thoroughly mixed with sand and then cement added keeping
mixer on until the material is uniform in appearance, suitable to receive water which at this
stage be added in sufficient quantity to produce the mix stuff workable, uniform in colour and
consistency.
To improve the workability of the mix, the hydrated lime, sand and water may first be mixed in
the required proportion with allowance to stand undisturbed for at least 16 hours before mixing
with cement. If allowed to stand for a longer period, the ingredients mix must be protected
from drying out. The whole of the batch shall be used within an hour of being mixed
Application of the various plaster or render coats
The work shall not start until the background has been prepared and all the services have
been finished according to requirement and the relevant specifications as described earlier.
Slurry coat shall be trowel applied allowing at least one day to start the succeeding coat
Two render coat applications shall be carried out.
Before applying any coat, the background or the preceding coat shall be brushed down to
remove any loose particles and dampened sufficiently to ensure uniform absorption.
First coat shall be trowel applied and scored to form a key for the second coat allowing at least
one day before the start of the next coat. The undercoat shall be applied either by laying on
with or throwing from a trowel or float, as uniformly thick as possible and not less than 8 mm or
more than 13 mm thick in any part.
The undercoat shall be left rough and open by the edge of the trowel after it has been long
enough to set firm, be combed with evenly spaced wavy horizontal lines approximately 20 mm
apart and 5 mm deep (less in case of first coat on metal lathing). The surface shall not be
scratched, however, when it is to receive a Tyrolean finish.
First undercoat applied to metal lathing shall be well worked into the lath to ensure that the
material is completely embedded.
The finishing coat shall be steel trowel applied
The finishing coat shall not be less than 5 mm or more than 10 mm thick and shall be laid on
with a trowel and finished with a steel float, taking care not to over work the surface.
All coats shall be applied with firm pressure to exclude air and to ensure a good bond.
Plaster shall be rodded and straightened to uniform surfaces in true planes. Laps of one coat
shall not occur over laps of preceding coat. Each coat shall finish free from cracks, checks or
other structural defects. Finish surfaces shall be flush with grounds / stop beads, corner
beads, outlet boxes and similar details, free from trowel marks, other blemishes displaying
straight arises and true angles.
All coats shall be prevented from drying out too quickly and the work be carried out in shade
during hot period. All renderings shall be protected by properly constructed hessian or similar
screen during hot period


Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              78 of



Each coat shall be kept damp by means of a fog spray of water for a minimum of 3 days to
allow before a subsequent coat is applied or in the case of a finish coat, before the protective
screens are removed
The surface of the finish coat shall be smooth, true and free from waviness, irregularities or
blemishes with straight, level or plumb angles. External angles shall be pencil rounded
Care shall be taken when rendering up to beads or stops to avoid excessive polishing at the
arris and damage to the galvanizing.
Inspections for the approval shall be conducted.
Equipment
Mixer
Attachment.
None
#36

Administration building
Roofing system
         Top
Index
Scope
Definitions
Responsibilities
Safety
Material
Method
Equipment
Attachment

Scope
This statement is aimed to present the procedures, sequences of operations and all the other
details that shall be worked on the proposed roofing system to be laid over the suspended roof
slabs.
Reference documents
Drawings Nos.
Specifications, Construction practice
Definitions
PSM           Project Site Manager.
CM            Construction Manager.
CS            Construction Superintendant
FM            Foreman

Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              79 of




Responsibilities
CM shall plan and organise the works to be carried out by the specialist contractor in
accordance with this Method Statement.
The Construction superintendent shall control , monitor and direct the Foreman regarding the
operations as required
The Construction Foreman and the supervisor of the specialist contractor shall execute the
work according to the CS direction and direct the work personnel to carry out the operations as
per Site requirements.
Safety
Prior to the commencement of work, the labour force shall receive the tool box talk on the
Project Site Safety requirements. Any process that is adopted which may have a particular
Safety risk, shall be assessed as required as per Site conditions and shall be taken care of. In
addition the work shall not be carried out during fast winds and dust storms. All workers shall
use masks and safety glasses in addition to other PPE.
The insulation boards shall be protected from the excessive exposure to sunlight.
Specialist Contractor
Materials
DERBIT PASTA, DERBIGUM UNIGUM, MGP, ROOF MASTER, TERRAM 700, PRECAST
CONCRETE TILES 500 X500 X50 MM form part of MAR 046 were approved subject to the
comments .
The clarification on the DERBIGUM MGP – This is the membrane flashing from the same manufacturer
of horizontal membrane and is a product finished with mineral granules to make it solar reflective as
well as UV resistant, shall be used for the reason that:
It is not recommended to mix a self adhesive membrane with a torch applied membrane as both are not
compatible
From the experience in this climate it has been observed that the textured Aluminium faced membrane
tends to delaminate after a few months if left exposed (due to the different co –efficient of expansion
between the metal and the bitumen)
For the aforesaid reasons the manufacturer recommend a mineral granules faced membrane as these
special solar reflective granules are spread over the bitumen while still hot and form part of the roof
membrane.This flashing membrane complements the main roof membrane and with this combination
on vertical exposed areas the performance is guaranteed for the specified period.
Aluminium Flashing- MAR 113 Dated 8.2.2000
It is confirmed that the proposed Aluminium Flashing for the roof upstands is a plain mill finish
manufactured to BS 1470 / ASTM B 209 Alloy, H 14 mill finish
Method
The roofing system shall be carried out to the following operational sequences.
Construction of all large foundation pads if any, prior to the commencement of the system
laying.
Preparing the proposed area over RCC slab, parapet walls and upstands ready by fixing in
positions all roof drains, cleaning the roof etc.,
Laying the Light Weight screed using foam concrete
Constructing an angle fillet around


Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              80 of



Priming with DERBIT PASTA and applying DERBIGUM UNIGUM the water proofing
membrane over the screed.
Applying flashing membrane MGP over the vertical exposed part of water proofing layer
Water test for 72 hours
Laying ROOF MASTER insulation boards 75 mm thick
Laying in TERRAM 700 membrane
Laying loose the precast concrete tiles 500 x 500 x 50 mm
Installing Aluminium flashing as specified and approved
On the existing RCC suspended slab all large foundations if any, shall be constructed prior to
commencing any roofing system operation. A groove shall be formed around the periphery of
the area, pad foundations and other upstands at a specified height from the slab level for
tugging the water proofing membrane into the parapet with sealant applied over.
All services drains or other necessary items required to be in place prior to the roofing starts
shall be completed in all respects including grouting. The area shall be cleared and made dry.
Inspection shall be conducted.
The lightweight screed using special foam concrete shall be laid in to the following mix design
to produce a density of 650 to 750 Kgs / cum
Sand / Cement: 1 / 1
Cement:                350 Kg / cum
Sand:                  350 Kg / cum
Water:                 210 Lit / cum
Foaming agent:         1.2 Lit / cum
The ingredients shall be mixed using a mechanical mixer, an aerator and a pump.
The surfaces to be laid with screed shall be formed using mortar dabs to the specified profiles
to 1 % slope. The foam concrete screed shall be laid in two layers to avoid settlement. The
second layer shall be laid when the first has dried out followed by forming smooth finish to the
required falls and cross-falls
Inspection shall be conducted
The completed screed shall be cured with fresh water for two days and thereafter, left for one
day to dry out.
A cement sand angle fillet of 50 x 50 mm triangular cross section shall be formed at all
directional changes.
Before laying in water proofing membrane, a coat of DERBIT PASTA bituminous primer shall
be applied to all the proposed surfaces.
Once dried, laying in 4 mm DERBIGUM UNIGUM membrane shall be commenced with by full
torching over the primed screed allowing 100 mm wide side and end overlaps. The dressing
shall be carried out over the angle fillet and upstands properly terminating into the preformed
grooves by tugging the membrane into the groove as well as rainwater outlets and around
penetrations.
The exposed vertical surface of the membrane shall be protected by applying 4 mm thick MGP
flashing membrane 300 mm girth, mineral surface finished, UV resistant, torched over main
membrane and tugged into groove as aforesaid.
Inspection shall be conducted

Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              81 of



The surface shall be flooded with water for a period of 72 hours after plugging in all the roof
drains
After successful completion of the test, water shall be drained out and the membrane left for
being dried out. The ROOF MASTER insulation boards with rebated edges 75 mm thick shall
be laid over the dry membrane ensuring all areas are properly covered.
The TERRAM 700-filter membrane with 100 mm overlaps shall be laid over top of the
insulation boards. All small and light precast pedestals / foundations for the cable trays, pipe
supports etc., if any, shall be loosely laid over the filter membrane.
Inspection shall be conducted by the manufacturer‟s representative and all coordinations
made.
A warranty for the specified period of 10 years shall be issued by the specialist contractor and
the Civil Contractor according to the contract requirement
The concrete paviors in the form of pre cast concrete tiles 500mm x 500 mm x 50 mm shall be
laid loose over the ITALPROFILI PVC TILE PADS to be provided at all the intersections and
at the corners as shown on the sketch. At the borders where cut tiles may be required, gravels
of nominal size 15 – 30 mm filling shall be carried out to create a good aesthetic.
The membrane shall be tugged into the groove and sealed with JOINT SEAL bituminous
Mastic.
Plain mill Aluminium flashing 0.90mm thick, 80 mm girth, cut and bent to the required profile
shape shall be fixed with stainless steel screws above the groove covering and protecting the
sealant all according to details.
Major Equipment
Mixer
Aerator
Pump
Attachment
#37


Buildings Roofing                                                                                system
Top

Index
Scope
Safety
Material
Method
Equipment
Attachment
Scope
This statement is aimed to propose the procedures to be adopted to carry out the operations
on the proposed roofing system over the suspended slabs on buildings.
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              82 of




Reference documents
Drawings Nos.
Specifications, Construction practice
Safety
Prior to commencement of any activity, the labour force shall receive a STARRT Card /
Toolbox Talk relevant to the operation concerned on the project site safety requirements.
Necessary measures shall be applied to any process involving a safety risk
A competent inspector shall visit the area daily to assess the safety measures adopted. Any
snag observed during his visit shall be notified to the supervisor present who immediately act
to bring the safety measures to an acceptable standard
Specialist Contractor
M / S Al Nahda Contracting and Trading Company Limited
PO Box # 1053, Sharjah
Materials
DERBIT PASTA, DERBIGUM UNIGUM, MGP, ROOF MASTER, TERRAM 700, PRECAST
CONCRETE TILES 500 X500 X50 MM form part of MAR                  were approved subject to the
comments.
The clarification on the DERBIGUM MGP – This is the membrane flashing from
the same manufacturer of horizontal membrane and is a product finished with
mineral granules to make it solar reflective as well as UV resistant, shall be used
for the reason that:
It is not recommended to mix a self-adhesive membrane with a torch-applied membrane, as
both are not compatible
From the experience in this climate it has been observed that the textured Aluminium faced
membrane tends to delaminate after a few months if left exposed (due to the different co –
efficient of expansion between the metal and the bitumen)
For the aforesaid reasons the manufacturer recommend a mineral granules faced membrane
as these special solar reflective granules are spread over the bitumen while still hot and form
part of the roof membrane. This flashing membrane complements the main roof membrane
and with this combination on vertical exposed areas, the performance is guaranteed for the
specified period.
Aluminium Flashing- MAR
It is confirmed that the proposed Aluminium Flashing for the roof upstands is a plain mill finish
manufactured to BS 1470 / ASTM B 209 Alloy, H 14 mill finish
Method
The roofing system shall be carried out to the following operational sequences.
On the existing RCC suspended slab all large foundations if any, shall be constructed prior to
commence any roofing system operation. A groove shall be formed around the periphery of the
area, on the pad foundations and other upstands at a specified height from the slab level for
tugging waterproofing membrane into the parapet with sealant applied over.


Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              83 of



All services drains or other necessary items required to be in place prior to the roofing
commences, shall be completed in all respects including grouting. The area shall be cleared
and made dry.
An Civil Contractor QC Inspection shall be conducted.
The lightweight screed using special foam concrete shall be laid in to the following mix design
to produce a density of 650 to 750 Kgs / cum
Sand / Cement: 1 / 1
Cement:                  350 Kg / cum
Sand:                   350 Kg / cum
Water:                  210 Lit / cum
Foaming agent:          1.2 Lit / cum
The ingredients shall be mixed using a mechanical mixer, an aerator and a pump.
The surfaces to be laid with screed shall be formed using mortar dabs to the specified profiles
to 1 % slope. The „foam concrete screed‟ shall be laid in two layers to avoid settlement. The
second layer shall be laid when the first has dried out followed by forming smooth finish to the
required falls and cross-falls
An Civil Contractor QC Inspection shall be conducted
The completed screed shall be cured with fresh water for two days and thereafter, left for one
day to dry out.
A cement sand angle fillet of 50 x 50 mm triangular cross section shall be formed at all
directional changes.
Before laying water proofing membrane, a coat of DERBIT PASTA bituminous primer shall be
applied to all the proposed surfaces.
Once dried, laying in 4 mm DERBIGUM UNIGUM membrane shall be commenced with by full
torching over the primed screed allowing 100mm wide side and end overlaps. The dressing
shall be carried out over the angle fillet and upstands properly terminating into pre formed
grooves by tugging the membrane into the groove as well as rainwater outlets and around
penetrations.
Exposed vertical surface of the membrane shall be protected by applying 4 mm thick MGP
flashing membrane 300 mm girth, mineral surface finished, UV resistant, torched over main
membrane and tugged into groove as aforesaid.
Application on the AC foundation & upstands shall be carried out according to the details
shown on the sketch
A Civil Contractor QC Inspection shall be conducted & ITP signed off
Whole surface shall be flooded with water for a period of 72 hours after plugging in all roof
drains
After successful completion of the test, water shall be drained out and the membrane left to dry
out. ROOF MASTER insulation boards with rebated edges 75 mm thick shall be laid over the
dry membrane ensuring all areas are properly covered.
TERRAM 700-filter membrane with 100-mm overlaps shall be laid over top of the insulation
boards. All small and light pre cast pedestals / foundations for the cable trays, pipe supports
etc., if any, shall be loosely laid over the filter membrane.
An inspection shall be conducted by the manufacturer‟s representative and all coordination
made.
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              84 of



A warranty for the specified period of 10 years shall be issued by the specialist contractor and
the Civil Contractor according to the contract requirement
Concrete paviors in the form of pre cast concrete tiles 500mm x 500 mm x 50 mm shall be laid
loose over ITALPROFILI PVC TILE PADS to be provided at all the intersections and at the
corners as shown on the sketch. At the borders where cut tiles may be required,
gravel(nominal size 15 – 30 mm) filling shall be carried out to create a good aesthetic.
The membrane shall be tugged into the groove and sealed with JOINT SEAL bituminous
Mastic.
Plain mill Aluminium flashing 1 mm thick, 80 mm girth, cut and bent to the required profile,
shall be fastened with stainless steel screws above the groove, covering and protecting the
sealant all according to details.
Major Equipment
Mixer, Aerator, Pump
Attachment
Sketch (Typical upstands and at AC Foundation)
Sub Contractor‟s method Statement
Clarification regarding DERBIGUM MGP
Clarification regarding Aluminium Flashing
Clarification regarding 10 years guarantee
Clarification regarding 72 hours water test
#38

Buildings Roofing system
Top


Index
Scope
Safety
Material
Method
Equipment
Attachment
Scope
This statement is aimed to propose the procedures to be adopted to carry out the operations
on the proposed roofing system over the suspended slabs on buildings.
Reference documents
Drawings Nos.
Specifications, Construction practice



Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              85 of




Safety
Prior to commencement of any activity, the labour force shall receive a STARRT Card /
Toolbox Talk relevant to the operation concerned on the project site safety requirements.
Necessary measures shall be applied to any process involving a safety risk
A competent inspector shall visit the area daily to assess the safety measures adopted. Any
snag observed during his visit shall be notified to the supervisor present who immediately act
to bring the safety measures to an acceptable standard
Specialist Contractor
M / S Al Nahda Contracting and Trading Company Limited
PO Box # 1053, Sharjah
Materials
DERBIT PASTA, DERBIGUM UNIGUM, MGP, ROOF MASTER, TERRAM 700, PRECAST
CONCRETE TILES 500 X500 X50 MM form part of MAR 046 were approved subject to the
comments.
The clarification on the DERBIGUM MGP – This is the membrane flashing from the same
manufacturer of horizontal membrane and is a product finished with mineral granules to make
it solar reflective as well as UV resistant, shall be used for the reason that:
It is not recommended to mix a self-adhesive membrane with a torch-applied membrane, as
both are not compatible
From the experience in this climate it has been observed that the textured Aluminium faced
membrane tends to delaminate after a few months if left exposed (due to the different co –
efficient of expansion between the metal and the bitumen)
For the aforesaid reasons the manufacturer recommend a mineral granules faced membrane
as these special solar reflective granules are spread over the bitumen while still hot and form
part of the roof membrane. This flashing membrane complements the main roof membrane
and with this combination on vertical exposed areas, the performance is guaranteed for the
specified period.
Aluminium Flashing- MAR
It is confirmed that the proposed Aluminium Flashing for the roof upstands is a plain mill finish
manufactured to BS 1470 / ASTM B 209 Alloy, H 14 mill finish
Method
The roofing system shall be carried out to the following operational sequences.
On the existing RCC suspended slab all large foundations if any, shall be constructed prior to
commence any roofing system operation. A groove shall be formed around the periphery of the
area, on the pad foundations and other upstands at a specified height from the slab level for
tugging waterproofing membrane into the parapet with sealant applied over.
All services drains or other necessary items required to be in place prior to the roofing
commences, shall be completed in all respects including grouting. The area shall be cleared
and made dry.
A Civil Contractor QC Inspection shall be conducted.
The lightweight screed using special foam concrete shall be laid in to the following mix design
to produce a density of 650 to 750 Kgs / cum
Sand / Cement: 1 / 1
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              86 of



Cement:                  350 Kg / cum
Sand:                   350 Kg / cum
Water:                  210 Lit / cum
Foaming agent:          1.2 Lit / cum
The ingredients shall be mixed using a mechanical mixer, an aerator and a pump.
The surfaces to be laid with screed shall be formed using mortar dabs to the specified profiles
to 1 % slope. The „foam concrete screed‟ shall be laid in two layers to avoid settlement. The
second layer shall be laid when the first has dried out followed by forming smooth finish to the
required falls and cross-falls
A Civil Contractor QC Inspection shall be conducted
The completed screed shall be cured with fresh water for two days and thereafter, left for one
day to dry out.
A cement sand angle fillet of 50 x 50 mm triangular cross section shall be formed at all
directional changes.
Before laying water proofing membrane, a coat of DERBIT PASTA bituminous primer shall be
applied to all the proposed surfaces.
Once dried, laying in 4 mm DERBIGUM UNIGUM membrane shall be commenced with by full
torching over the primed screed allowing 100mm wide side and end overlaps. The dressing
shall be carried out over the angle fillet and upstands properly terminating into pre formed
grooves by tugging the membrane into the groove as well as rainwater outlets and around
penetrations.
Exposed vertical surface of the membrane shall be protected by applying 4 mm thick MGP
flashing membrane 300 mm girth, mineral surface finished, UV resistant, torched over main
membrane and tugged into groove as aforesaid.
Application on the AC foundation & upstands shall be carried out according to the details
shown on the sketch
A Civil Contractor QC Inspection shall be conducted & ITP signed off
Whole surface shall be flooded with water for a period of 72 hours after plugging in all roof
drains
After successful completion of the test, water shall be drained out and the membrane left to dry
out. ROOF MASTER insulation boards with rebated edges 75 mm thick shall be laid over the
dry membrane ensuring all areas are properly covered.
TERRAM 700-filter membrane with 100-mm overlaps shall be laid over top of the insulation
boards. All small and light pre cast pedestals / foundations for the cable trays, pipe supports
etc., if any, shall be loosely laid over the filter membrane.
An inspection shall be conducted by the manufacturer‟s representative and all coordination
made.
A warranty for the specified period of 10 years shall be issued by the specialist contractor and
the Civil Contractor according to the contract requirement
Concrete paviors in the form of pre cast concrete tiles 500mm x 500 mm x 50 mm shall be laid
loose over ITALPROFILI PVC TILE PADS to be provided at all the intersections and at the
corners as shown on the sketch. At the borders where cut tiles may be required,
gravel(nominal size 15 – 30 mm) filling shall be carried out to create a good aesthetic.

Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              87 of



The membrane shall be tugged into the groove and sealed with JOINT SEAL bituminous
Mastic.
Plain mill Aluminium flashing 1 mm thick, 80 mm girth, cut and bent to the required profile,
shall be fastened with stainless steel screws above the groove, covering and protecting the
sealant all according to details.
Major Equipment
Mixer, Aerator, Pump
Attachment
Sketch (Typical upstands and at AC Foundation)
Sub Contractor‟s method Statement
Clarification regarding DERBIGUM MGP
Clarification regarding Aluminium Flashing
Clarification regarding 10 years guarantee
Clarification regarding 72 hours water test
#39

Cracked gas compressor table top concrete
pour
Top
 Index
Scope
Reference documents
Definitions
Responsibilities
Safety
Method including traffic management scheme
Equipment
Attachment

Scope
This statement is aimed to present the proposed procedures to be adopted to pour the Table
Top of the framed beam structure.
References
Drawing nos.
Specifications and Rev D
Safety
Prior to the commencement of work, the labour force shall receive the tool box talk on the
Project Site Safety requirements. Any process that is adopted which may have a particular
Safety risk, shall be assessed as required as per Site conditions and shall be taken care of. In
addition proper scaffolding according to the project requirements shall be erected around the
area to be poured along with providing complete access system such as stepped stairs and
the working platforms with top and the bottom guardrails.
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              88 of



The area shall be cleared on ground allowing free access to the concrete pumps, transit
mixers water tank etc., and the provision of the night lights shall be made for curing
Materials
The gross volume of the pour is 173 cum
The volume of the steel plates inserts is 1.08 cum
The applicable volume of the pour is 170 cum approximately.
(Details of the calculations attached).
According to the specification the pour pertains to the definition of massive structure, hence
C 30 high slag blast furnace cement to BS 4246 with 70 % replacement utilising 30 % ASTM
C 150 Type II cement shall be utilised for the batching according to the specified design mix
with the placing temperature not more than 24 degree Celcius
Curing materials such as curing compound, polythene sheets, bur lap sheets / hessians and
water shall be available according to the requirement
Plants and Equipment
Batching plant        1 # and 1 standby
Concrete pump         1 # and 1 stand by
Transit mixers        6#
Vibrator              2 # and 2 standby
Water tanker           1#
Manpower
Masons                  6#
Carpenters              3#
Steel fixers           3#
Scaffolder             3#
Helpers                 7#
Method
The drawing shows the above pour to be carried out into 13 sections by forming 16
construction joints. Pour sequences are described as Pour „A‟ and Pour‟B‟. A total of 5 pours
„A‟ sections, all shown to be concreted prior to Pour „B‟. Remaining 16 Pours „ B‟ sections
shown to be concreted after 14 days of the Pour „A‟ completion. But according to the decision
vide STQ , the Table Top shall be poured one time monolithically without formation of any
construction joint.
The quantitities involved have been detailed in the attachment.
The overall procedures that shall be carried out have been given as follows
Erection for the preparatory works horizontal forms for the complete pour based on the
properitory details from SGB drawings
Placing the insert plates on the horizontal forms and if required some tangs be welded or tied
by binding wires to the rebars by link rebars
Placing the holding down bolts sleeves in the proper locations as shown on the drawings
Placing and binding all the design rebars to the drawings‟ details.
Placing and fixing the vertical and the top plates on the vertical forms.
Erecting preparatory works vertical forms in positions


Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              89 of



Aligning all forms, the insert plates and the bolt sleeves from the shown ‟ centre line of
Turbine Exhaust axis‟ to be used as a reference line.
Inspection and approvals.
Pouring details
The pour shall commence from East End and be accomplished in 4 layers according to the
attached sequences details proportioned in 12 sections.
The concrete temperature shall not be more than 24 degree Celcius as specified for the
massive structures.
Immediately after pouring is finished, curing compound shall be sprayed and the surface be
covered with polythene membrane.
Lator within 2 hours polythene shall temporarily be lifted, the saturated hessian spread and the
polythene relaid.
A layer of insulation material 100 mm thick shall be laid over the polythene, covered with ply
sheets to keep the insulation material intact / in place for 72 hours for thermal curing, and
thereafter, the routine curing shall continue for the specified period.
The differential thermometers shall be used to record the temperature variations.
Attachment
Q.A. Procedures
Pour sequence plan
Pour quantities
Insert plates volume




#40

Water tightness tests for the collection
sumps according to BS 8007:1987 section 9
 Top
Index
Scope
Reference documents
Definitions
Responsibilities
Safety
Method
Equipment
Attachment

Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              90 of




Scope
This statement is aimed to present the proposed procedures(Typical) that shall be adopted to
conduct the water tightness tests for the following water retaining structures.
Collection sump Utilities East
Collection sump Ethylene
Collection sump Utilities East
Collection sump Utilities South
References
Definitions
PSM                      Project Site Manager
CSM                      Construction Manager
CS                       Construction Superintendent
FM                       Foreman
QC                       Quality Control
Responsibilities
PSM shall control the overall operations
CM shall arrange the resources required accordingly
CS shall control, monitor and direct the FM and workforce for the operations
FM shall execute the operations deploying the workforce
QC shall inspect all the operations according to the specifications
EPC Contractor shall conduct surveillance
Safety
Prior to the commencement of work, the labour force shall receive the toolbox talk on the Project Site
Safety requirements. Any process that is adopted which may have a particular Safety risk, shall be
assessed to the requirement for Site conditions and be taken care of. The safety barricades shall be
erected around the sumps.
Night hazard indicator light illuminaries shall be installed on the necessary locations.
No unauthorised persons shall be allowed to enter the test area.
Materials
Water requirements
For 70-TB-201                          370 cum and 5                  % for stabilisation period
For 70-TB-202                           237cum and 5                  % for stabilisation period
For 70-TB-203                           166cum and 5                  % for stabilisation period
For 70-TB-205                           191cum and 5                  % for stabilisation period
Method
This test requires the following operational sequences to be completed prior to
conductance such as
Complete RCC construction of the structure
Complete filling of the tie rod holes with MBT Master Flow 544
External Protection to the concrete surfaces with Bitustick XL, Polybit- Corrotech
Civil Contractor QC Inspection and the approval of the membrane
Structural Backfilling around the tank to the required level with compaction tests
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              91 of



Cleaning the surface of the structure by using waterjetting
Application of the floor screed as specified
The following operations shall be required to conduct the water tightness test
A graduated stick shall be provided on wall top to show the water levels to a‟ mm‟ count
Filling the structure with potable water to the maximum supply level
After water filling, 7 days allowance to stabilise for absorption and autogeneous healing.
Test to be conducted for 7 days for a design crack width of 0.1 mm.
Recording the water losses at 24 hours intervals by simple measurements or by float indicator.
Monitoring the seepage and marking the locations.Recording level losses
After the test completion, pumping the water out and transporting off the site.
Post water tightness test
MBT shall produce a representative sample for approval prior to the coating is applied
Approval of the sample by EPC Contractor / Client
Applying the concrete protection approved coating material according to the representative
sample on the internal surfaces of the structure as specified.
Inspection of the applied coating by Civil Contractor QC followed by EPC Contractor approval
Details
70-TB-201 / 202 / 203 Inlet pipes 600 mm dia and for 205 inlet pipes 450 and 400 mm dia to
be in place according to the levels shown on the drawings as reflected on the schedule as the
Inverted level for maximum supply level.
The structure to be tested shall be completed of all RCC constructions according to the
specified and agreed procedures.
The tie rod holes shall be filled with Master Builder Technology MBT Masterflow 544
according to the instructions
The external surfaces of the structure shall be prepared for the specified application
Inspection of the prepared surface by Civil Contractor QC followed by EPC Contractor
approval
The external surfaces of the concrete around shall be applied with the specified protective
system Bitustick XL, Polybit
Inspection of the applied membrane by Civil Contractor QC followed by EPC Contractor
approval
Structural backfilling shall be carried out according to the project specifications
Necessary fileld density tests shall be conducted by Civil Contractor and laboratory
All the aforesaid operations shall be completed prior to the commencement of the water
tightness test
The structure to be tested shall be cleaned to the requirement by using waterjetting on the
entire surface of concrete removing all loose spalls, dust dirt etc.,
The internal surfaces shall be inspected by Civil Contractor QC followed by EPC Contractor
approval
Civil Contractor QC Inspection shall be conducted before the test commences
EPC Contractor approval shall be obtained.
Water tightness test shall be conducted according to the BS 8007 : 1987 Section 9.1
applicable to liquid retaining structures

Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              92 of



Potable water shall be filled into the respective sump pit structures at a rate 2 m per 24 hours
for which the attached filling scheduled quantities shall apply.
The records of the test shall be documented on the attached sample form QCF 61
STRUCTURE LEAK TEST form and the judgement on the test shall be made accordingly
SCHEDULE PLANNED FOR THE PROPOSED TEST

S          DESCRIPTION OF OPERATION              NUMBER                                                           REMARK
#                                                OF DAYS
1        Filling potable water in sump pit 1m 1                                                                   By tankers filled at a uniform
         deep below the base level of the catch                                                                   Rate not greater than 2 m in 24
         pit and 1 m depth above the base slab                                                                    hours
         to make a total depth 2 m
2        Filling potable water another 2 m depth 1                                                                By tankers
         to make 4 m
3        Filling potable water the remaining 1                                                                    By tankers
         depth to maximum supply level
4        Stabilisation period to allow for 7                                                                      Additional water to be filled if
         absorption and autogenous healing                                                                        required
5        Testing period to record the water loss 7                                                                Monitoring regarding seepage
         by seepage and by evaporation every                                                                      loss and the provision of 1 /
         24 hours                                                                                                 500 of average depth or 10mm.
                                                                                                                  (Visual inspection)
6        Pumping the filled water out offsite                                             1                       To the other structure for test
7        Total period of water Test                                                       18 Days

The potable water shall be filled by the water tankers to the above schedule upto the maximum
level.
A 7 days stabilisation period shall be allowed for water absorption and autogenous healing for
the requirement for a maximum design crack width 0.1 mm .The water level shall be
maintained by filling in further water for stabilisation.
After the stabilisation period, monitoring for the water loss excluding the evaporation shall be
conducted every 24 hours either employing the level floats or manometers or by simple daily
measurements.
The observations shall be recorded on the form QCF 61 Structure Leak Test for
documentation
During this 7 days period the total permissible loss in level shall not exceed 1 / 500 of the
average water depth of the full tank or 10 mm.
After the test is successfully completed, the water shall be pumped out either to the other
structure for testing should that be ready to receive it or if not, the other construction areas for
curing or any other purpose as agreed leaving the pit empty.
The application of the internal protective specified coating shall be carried out to the
manufacturer‟s instructions
Civil Contractor QC inspection shall be conducted followed by the EPC Contractor approval

Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              93 of



Remedial Work if required
In case of unsatisfactory performance of the water tightness test and upon the agreement with
EPC Contractor, injection grouting method shall be adopted to seal the seepage routes.
Should the structure not satisfy the 7 days test then after the completion of the remedial work it
should be refilled and if necessary left for a further stabilising period; a further test of 7 days‟
duration should then be undertaken in accordance with this clause.
Equipment
Water Tanker
Pump, sweep blasting package etc.,
Graduated stick
Attachment
Water quantity schedule
Documentation form QCF for structural leak test
Sketch
Sub Contractor‟s method Statement
Clarification regarding DERBIGUM MGP
Clarification regarding Aluminium Flashing
Clarification regarding 10 years guarantee
Clarification regarding 72 hours water test

#41

Water tightness tests for the collection
sumps according to BS 8007:1987 section 9
Top
Index
Scope
Reference documents
Safety
Method
Equipment
Attachment
Scope
This statement is aimed to present the proposed procedures (Typical) that shall be adopted to
conduct the water tightness tests for the following water retaining structures.
Collection sump 70-TB-201            Utilities East
Collection sump 70-TB-202            Ethylene
Collection sump 70-TB-203            Utilities East
Collection sump 70-TB-205            Utilities South
References
Specification, Clause 7.0, Crack Control
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              94 of




Safety
Prior to commence any activity, the labour force shall receive a STARRT Card / Toolbox Talk
relevant to the operation concerned on the project site safety requirements.
Necessary measures shall be applied to any process involving a safety risk
Safety Supervision
A competent inspector shall visit the area daily to assess the safety measures adopted. Any
snag observed during his visit shall be notified to the supervisor present who immediately act
to bring the safety measures to an acceptable standard
Materials
Water requirements
For 70-TB-201          370 cum and 5 % for stabilisation period
For 70-TB-202          237cum and 5 % for stabilisation period
For 70-TB-203          166cum and 5 % for stabilisation period
For 70-TB-205          191cum and 5 % for stabilisation period
Method
The structure to be tested shall be completed of all RCC constructions according to the
specified and agreed procedures.
Complete filling of the tie rod holes with MBT Master Flow 544 shall be carried out according to
the manufacturer‟s instructions
70-TB-201 / 202 / 203 Inlet pipes 600 mm dia and for 70-TB-205 inlet pipes 450 and 400
mm dia shall be laid in place to the levels shown on the drawings as reflected on the water
quantity schedule i.e the Invert levels at maximum supply elevations.
The external surfaces of the structure shall be prepared & applied with the specified protective
system Bitustick XL, Polybit
Civil Contractor QC Inspection shall be conducted for the approval of the membrane
Structural backfilling shall be carried out externally to the project specifications & necessary
field density tests conducted to the requirement
Application of the floor screed as specified shall be carried out
The entire surfaces of structure to be tested shall be sweep blasted removing all loose spalls,
dust dirt etc.,
The prepared internal surfaces shall be inspected by Civil Contractor QC for approval
The following operations shall be involved to conduct the water tightness test according to the
BS 8007 : 1987 Section 9.1 applicable to liquid retaining structures
A graduated stick shall be provided on wall top to show the water levels to a‟ mm‟ count
Potable water shall be filled into the respective sump pit structure at a rate 2 m per 24 hours
for which the attached „filling scheduled quantities „shall apply.
After water is filled in to the required level, it shall be allowed to stay for a period of 7 days for
stabilisation, absorption and autogeneous healing. If so required, water shall be added to
maintain the maximum test level in case it is lost during this period.
Test shall commence from 8th day and continue for 7 days for a design crack width of 0.1 mm
according to specification requirement.
Observations regarding water level drops shall be recorded every 24 hours by visual
measurements on mm scale
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              95 of



The test records shall be documented on the attached form QCF
„ STRUCTURE LEAK TEST „and the judgement on the test made accordingly
During this 7 days period the total permissible loss in level shall not exceed 1 / 500 of the
average water depth of the full tank or 10 mm.
After the test is successfully completed, water shall be pumped out either to the other structure
for testing should that be ready to receive it or if not, to the other construction areas for curing
or any other purpose as agreed leaving the pit empty.
Remedial Work if required
In case of unsatisfactory performance of the water tightness test and upon the agreement with
EPC Contractor, injection grouting method may be adopted to seal the seepage routes.
Should the structure not satisfy the 7 days test then after the completion of the remedial work it
should be refilled and if necessary left for a further stabilising period; a further test of 7 days‟
duration should then be undertaken in accordance with this clause.

SCHEDULE PLANNED FOR THE PROPOSED TEST
S    DESCRIPTION OF OPERATION              NUMBER                                                                 REMARK
#                                          OF DAYS
1  Filling potable water in sump pit 1m 1                                                                         By tankers filled at a uniform
   deep below the base level of the catch                                                                         Rate not greater than 2 m in 24
   pit and 1 m depth above the base slab                                                                          hours
   to make a total depth 2 m
2  Filling potable water another 2 m depth 1                                                                      By tankers
   to make 4 m
3  Filling potable water the remaining 1                                                                          By tankers
   depth to maximum supply level
4  Stabilisation period to allow for 7                                                                            Additional water to be filled if
   absorption and autogenous healing                                                                              required
5  Testing period to record the water loss 7                                                                      Monitoring regarding seepage
   by seepage and by evaporation every                                                                            loss and the provision of 1 /
   24 hours                                                                                                       500 of average depth or 10mm.
                                                                                                                  (Visual inspection)
6        Pumping the filled water out offsite                                             1                       To the other structure for test
7        Total period of water Test                                                       18 Days

Post water tightness test
MBT shall produce a representative Masterseal 550 coating sample for approval by EPC
Contractor and the client. The internal surfaces shall be coated according to the approved
sample
Civil Contractor QC inspection shall be conducted to approve the applied coating
Equipment
Water Tanker, Pump, sweep blasting package etc.,



Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              96 of



Graduated stick
Attachment
Water quantity schedule
#42


Administration building Marble flooring
Top
Index
Scope
Reference documents
Definitions
Responsibilities
Safety
Method
Equipment
Attachment
Scope
This statement is aimed to propose the procedures to be adopted to carry out marble flooring
on the various room areas, FF Reception, Lobby, the stair case steps & landing
References
Drawing
EPC Contractor
UBC & General Construction Practice, STQ
MAR Dated 2.4.2000 Approved 4.4.2000 Perlato Royal marble for Administration Building
Reception, FF lobby & stairs
MAR Dated 12.3.2000 Approved 30.3.2000    Blue Pearl marble for Worktop and Toilet
Counters
Definitions
PSM          Project Site Manager
CSM          Construction Manager
CS           Construction Superintendent
SE           Site Engineer
FM           Foreman
QC           Quality Control
Responsibilities
PSM shall control the overall operations
CM shall arrange the resources required accordingly
CS shall control, monitor and direct the SE, FM and workforce for the operations
SE shall be responsible for all the site operations and follow the instructions of the CS
FM shall execute the operations deploying the workforce. FM shall explain in full in the
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              97 of



language the work persons understand about all the instruction and the ToolBox talks every
day and check that the same are followed up regularly
QC shall inspect all the operations according to the specifications
EPC Contractor shall conduct surveillance
Safety
The workers shall receive a ToolBox Talk according to the project requirement relevant to the
operation concerned every day prior to commencement of the activity
Proper illumination shall be provided in the dark area
The area to be laid with marble flooring system shall be closed for the general movement
except those working there and be opened only when the work has properly been completed
with hardboard cover protection spread on the newly laid finishes.
Only industrial cable / wires shall be used for the grinding machine with earthing arrangement
to avoid any shock or mishap
The personnel working around the grinding machine shall use eyeglasses and all other
Personal Protective Equipment
Safety Supervision
A competent inspector shall visit the area daily to assess the safety measures adopted. Any
snag observed during the inspection shall be notified to the supervisor present who
immediately act to bring the safety measures to an acceptable standard
Materials
Marble tiles 300x600x20mm (Directly placeable) and also Kitchen Work tops & toilet
Counters, Reception Area + Lobby First Floor- Perlato Royal (Placeable according to the
supplier‟s details)
(Al Ain Cement and Marble Product Co)
Proprietary Grout
Method
(Laying Marble Floor Tiles by SEMI DRY method)
The following activities are involved to carry out the marble flooring system
The areas of the concrete sub strata to be laid with marble shall be brush cleaned and
dampened until absorption ceases followed by the finished floor level establishment by means
of dots and rules
Total thickness for the marble flooring is 100 mm including 80 mm bedding screed
(1 cement: 4 mortar sand) by weight and shall be applied as described below
The finishing layer shall be marble tiles 20 mm thick and be laid as described below
Details
The mortar for bedding the tiles shall be 1 part cement to 4 parts sand by weight, mixed
semidry by a mechanical mixer with only sufficient water added to give a crumbly consistency
which retains its shape when squeezed by hand permitting no fluidity
The mix shall be placed to a thickness approximately 10 mm greater than that actually required
for the bed, thoroughly compacted by tamping and drawing off to the required level with a
screed board. Only sufficient mortar shall be mixed and spread as can be covered with tiles
before it attains its initial set.
Civil Contractor QC visual inspection shall be conducted
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              98 of



A slurry of 1 part cement to 1 part sand by volume shall be poured over the surface of the semi
– dry mix bedding and spread with a trowel until it is approximately 2 mm thick
Dry marble tiles / flags shall then be laid on the slurry and beaten firmly into position with a
wooden beater ensuring a true surface contact between the tiles and bedding is formed.
The marble tiles / flags shall be correctly positioned in both directions the time these are
placed
The tiles shall neatly and accurately be cut to a close fit where necessary at abutments,
around outlets, pipes and the like.
Civil Contractor QC Inspection shall be conducted for the correct formation of joint alignment
and the level profile followed by EPC Contractor approval
The tiles shall be laid level or tops to 1- % falls in ‘wet’ areas as may be required.
 The floor finishing shall be carried out using an electrically operated rotary grinding machine
fixed with a carborundum stone of varying grades for the uneven edges or the protrusions as
well as the fine range for the even areas to attain a smooth surface texture allowing water
lubrication.
The grinding runs shall depend on the finishing profile formed. More varying profile shall be
applied with additional grinding rotation till the acceptable one is achieved.
Plenty of water shall be used for this purpose. All the water shall be washed away after
the grinding is completed.
Civil Contractor QC Inspection shall be conducted for the correct formation of joint alignment
and the level profile followed by EPC Contractor approval
During grinding any portion damaged or effected badly shall be replaced to the specification
requirement. Minor blown up or damaged tile shall be grouted with the proprietary compatible
colour to match the marble texture
 A seal coat shall be applied on the ground surface with an approved proprietary polishing
material according to the manufacturer‟s instructions after which the finished surface be
cleaned, the arrangement to protect the finished areas be made by overlaying hardboards and
closing the entry in general.
MOVEMENT JOINTS IN TILED FLOORS
Unless otherwise indicated in the documents, a 10-mm movement joint shall be formed at the
perimeter of all the tiled floors and where the tiling meets structural features such as columns,
machine bases etc.
Where a structural movement joint is provided in the base, a movement joint of the same width
in the bedded finish shall be positioned immediately above
The movement joint cavities shall extend through the combined thickness of the finish and the
bedding mortar, completely filled and sealed after grouting of the normal joints takes place.
Other standard items such as treads, risers, worktops and the counters shall be cut to the
exact site dimensions with the wash basins and the sink blocks taken out. These preformed
items shall be supplied completed in all respects and fixed to the supplier‟s details
Major Equipment
Mechanical Mixer
Wheel barrows
Mason‟s tools in general
Grinding Machine with varying carborundum stone grades attachment
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              99 of




Attachment
#43

Ethylene gas compressor
Table top pour
       Top
Index
Scope
Reference documents
Definitions
Responsibilities
Safety
Material
Method
Equipment
Manpower
Attachment
Scope
This statement is aimed to present the proposed procedures to be adopted to pour the Table
Top of the framed beam structure.
References
Drawing No..
Specifications
Safety
Prior to the commencement of work, the labour force shall receive the tool box talk on the
Project Site Safety requirements. Any process that is adopted which may have a particular
Safety risk, shall be assessed to the requirement for Site conditions and be taken care of.
Proper scaffolding according to the project requirements shall be erected around the area to
be poured along with providing complete access system such as stepped stairs and the
working platforms with top and the bottom guard rails.
The area shall be cleared on ground allowing free access to the concrete pumps, transit
mixers water tank etc., and the provision of the night lights shall be made for curing
Materials
The gross volume of the pour is 81 cum
The volume of the steel plates inserts is 0.35 cum
The applicable volume of the pour is 80 cum apprx.
(Details of the calculations attached).
According to the specification the pour pertains to the definition of massive structure , hence,
C 30 high slag blast furnace cement to BS 4246 with 70 % replacement utilising 30 % ASTM
C 150 Type II cement shall be utilised for the batching according to the specified design mix
with the placing temperature not more than 24 degree Celcius.
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              100 of



Curing materials such as curing compound, polythene sheets, bur lap sheets / hessians and
water shall be available according to the requirement
Method
The drawing shows the above pour to be carried out into 7 sections by forming 8 construction
joints. Pour sequences are described as Pour „A‟ and Pour‟B‟. A total of 3 pours „A‟ sections,
all shown to be concreted prior to Pour „B‟. Remaining 4 Pours „ B‟ sections shown to be
concreted after 14 days of the Pour „A‟ completion. But according to the decision vide STQ, the
Table Top shall be poured one time monolithically without formation of any construction joint.
The quantitities involved have been detailed in the attachment. The overall procedures that
shall be carried out have been given as follows;
Erection for the preparatory works horizontal forms for the complete pour based on the
properitory details from SGB drawings
Placing the insert plates on the horizontal forms and if required some tangs be welded or tied
by binding wires to the rebars by link rebars
Placing the holding down bolts sleeves in the proper locations as shown on the drawings
Placing and binding all the design rebars to the drawings‟ details.
Placing and fixing the vertical and the top plates on the vertical forms.
Erecting preparatory works vertical forms in positions
Aligning all forms, the insert plates and the bolt sleeves from the shown ‟ centre line of
Turbine Exhaust axis‟ to be used as a reference line.
Inspection and approvals.
Pouring details
The pour shall commence from East End and be accomplished in 4 layers according to the
attached sequences details proportioned in 7 sections.
The concrete temperature shall not be more than 24 degree Celcius as specified for the
massive structures.
Immediately after pouring is finished, curing compound shall be sprayed and the surface be
covered with polythene membrane.
Lator within 2 hours polythene shall temporarily be lifted, the saturated hessian spread and the
polythene relaid.
 A layer of insulation material 100 mm thick shall be laid over the polythene, covered with ply
sheets to keep the insulation material intact / in place for 72 hours for thermal curing, and
thereafter, the routine curing shall continue for the specified period.
The differential thermometers shall be used to record the temperature variations.
Plants and Equipment
Batching plant            1 and 1 No. stand by
Concrete pump             1 and 1 No. stand by
Transit mixers            6 Nos.
Vibrator                  2 and 2 Nos. standby
Water tanker              1 No.
Manpower
Masons                 6 Nos.
Carpenters             3 Nos.
Steel fixers           3 Nos.
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              101 of



Scaffolder           3 Nos.
Helpers              7 Nos.
Attachment
QA Procedures
Pour sequence plan
Pour quantities
Insert plates volume
#44

Propane gas compressor
table top pour
Top
Index
Scope
Reference documents
Definitions
Responsibilities
Safety
Material
Method
Equipment
Manpower
Attachment
Scope
This statement is aimed to present the proposed procedures to be adopted to pour the Table
Top of the framed beam structure.
References
Drawing nos
Specifications
Safety
Prior to the commencement of work, the labour force shall receive the tool box talk on the
Project Site Safety requirements. Any process that is adopted which may have a particular
Safety risk, shall be assessed to the requirement for Site conditions and be taken care of.
Proper scaffolding according to the project requirements shall be erected around the area to
be poured along with providing complete access system such as stepped stairs and the
working platforms with top and the bottom guard rails.
The area shall be cleared on ground allowing free access to the concrete pumps, transit
mixers water tank etc., and the provision of the night lights shall be made for curing.
Materials
The gross volume of the pour is 60 cum
The volume of the steel plates inserts is 0.75 cum
The applicable volume of the pour is 58 cum apprx. (Details of the calculations attached).
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              102 of



According to the specification the pour pertains to the definition of massive structure , hence,
C 30 high slag blast furnace cement to BS 4246 with 70 % replacement utilising 30 % ASTM
C 150 Type II cement shall be utilised for the batching according to the specified design mix
with the placing temperature not more than 24 degree Celcius
Curing materials such as curing compound, polythene sheets, bur lap sheets / hessians and
water shall be available according to the requirement.
Method
The drawing shows the above pour to be carried out into 7 sections by forming 8 construction
joints. Pour sequences are described as Pour „A‟ and Pour‟B‟. A total of 3 pours „A‟ sections,
all shown to be concreted prior to Pour „B‟. Remaining 4 Pours „ B‟ sections shown to be
concreted after 14 days of the Pour „A‟ completion. But according to the decision vide STQ, the
Table Top shall be poured one time monolithically without formation of any construction joint.
The quantitities involved have been detailed in the attachment.
The overall procedures that shall be carried out have been given as follows
Erection for the preparatory works horizontal forms for the complete pour based on the
properitory details from SGB drawings
Placing the insert plates on the horizontal forms and if required some tangs be welded or tied
by binding wires to the rebars by link rebars
Placing the holding down bolts sleeves in the proper locations as shown on the drawings
Placing and binding all the design rebars to the drawings‟ details .
Placing and fixing the vertical and the top plates on the vertical forms.
Erecting preparatory works vertical forms in positions
Aligning all forms ,the insert plates and the bolt sleeves from the shown ‟ centre line of
Turbine Exhaust axis‟ to be used as a reference line.
Inspection and approvals.
Pouring details
The pour shall commence from East End and be accomplished in 4 layers according to the
attached sequences details proportioned in 5 sections.
The concrete temperature shall not be more than 24 degree Celcius as specified for the
massive structures.
Immediately after pouring is finished , curing compound shall be sprayed and the surface be
covered with polythene membrane.
Lator within 2 hours polythene shall temporarily be lifted, the saturated hessian spread and
the polythene relaid.
A layer of insulation material 100 mm thick shall be laid over the polythene, covered with ply
sheets to keep the insulation material intact / in place for 72 hours for thermal curing, and
thereafter, the routine curing shall continue for the specified period.
The differential thermometers shall be used to record the temperature variations.
Plants and Equipment
Batching plant            1 and 1 No. stand by
Concrete pump             1 and 1 No. stand by
Transit mixers            6 Nos.
Vibrator                  2 and 2 Nos. standby
Water tanker              1 No.
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              103 of



Manpower
Masons                                   6 Nos.
Carpenters                               3 Nos.
Steel fixers                             3 Nos.
Scaffolder                               3 Nos.
Helpers                                  7 Nos.
Attachment
Q.A. Procedures
Pour sequence plan
Pour quantities
Insert plates volume
#45

Expansion joints in ditches
Top
Index
Scope
Reference documents
Definitions
Responsibilities
Safety
Method
Equipment
Attachment
Scope
This statement is aimed to present the proposed procedures to be adopted to seal the
Expansion joints in the ditches.
References
Drawing nos
Safety
Prior to the commencement of work, the labour force shall receive the tool box talk on the
Project Site Safety requirements. Any process that is adopted which may have a particular
Safety risk, shall be assessed to the requirement for Site conditions and be taken care of.
The personnel working on this activity shall wear masks, safety glasses, gloves, etc.,
Method
To seal the expansion joints the following operations shall be carried out.
Cleaning of the joint surfaces.
Preparing and filling the joints with Bitumastic
Details
The size of the proposed joints to be filled / sealed is 15 mm wide x 15 mm deep



Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              104 of



Application procedure
The surface shall be cleaned of all dirt, dust and loosely adhering materials. All grease and oil
contamination shall be removed using hard small brushes, compressed air etc. The fibre board
shall be removed to the required depth.
Masking tape shall be used to confine the joint borders keeping the adjoining concrete
surfaces clean. The contents of the Can shall be removed by a Trowel or a Spatula.
The Bitumastic shall be applied to the prepared and masked portions.
In case of the vertical joints, bottom to top application sequence shall be followed ensuring that
the entire volume of the joint is filled in using a spatula or a trowel to effect a total contact with
joint surfaces.
After application, the sealant shall be smoothened and compressed into the joint using a
spatula or a putty knife moistened with cleaning solvent.
Masking tape shall be removed immediately after the application has been over to keep the
concrete surface clean.
It shall take 4-6 weeks post application normally to a full cure at a stage when the solvent
evaporation is completed. Over painting if so required, shall be carried out only after the full
cure has taken place.
Coverage
Coverage for joint depth 10 mm and width 15mm 6.5 kg of Bitumastic per linear metre
Equipment
Trowel
Spatula
Knife etc.,
Attachment
None
#46

Expansion joints in ditches
Top
Index
Scope
Reference documents
Safety
Method
Equipment
Attachment
Scope
This statement is aimed to propose the procedures to be adopted to seal the Expansion Joints
in the ditches.



Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              105 of



References
Drawing nos.
Specs:
BITUMASTIC, Manufacturer - Polybit
Safety
Prior to the commencement of work, the labour force shall receive a Toolbox talk on the
Project Site Safety requirements.
Necessary measures shall be applied for any process involving particular safety risk
Personnel working on this activity shall wear masks, Eye protection, gloves, etc.,
Method
Size of the proposed joints to be filled / sealed is 15 mm wide x 15 mm deep
The surface shall be cleaned of all dirt, dust and loosely adhering materials.
All grease and oil contamination shall be removed using hard small brushes, compressed air
etc.
The fibreboard shall be removed to the required depth.
Under normal circumstances priming is not required
Masking tape shall be used to confine the joint borders keeping the adjoining concrete
surfaces clean.
The contents of the Can shall be removed by a Trowel or a Spatula.
The Bitumastic shall be applied to the prepared and masked portions.
In case of the vertical joints, bottom to top application sequence using a spatula or a trowel,
shall be followed ensuring that the entire volume of the joint is filled in to effect a total contact
with joint surfaces.
After application, the sealant shall be smoothened and compressed into the joint using a
spatula or a putty knife moistened with cleaning solvent.
Masking tape shall be removed immediately after the application is completed to keep the
concrete surface clean.
A full cure (a stage when the solvent evaporation is completed) shall normally consume
4 to 6 weeks post application of the sealant
Painting over concrete surface if so required, shall be carried out only after full cure has taken
place.
Equipment
Trowel
Spatula
Knife etc.,
Attachment
Manufacturer Datasheet
#47

Concrete coating
Using master seal 550
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              106 of




Top
Index
Scope
Reference documents
Definitions
Responsibilities
Safety
Material
Method
Equipment
Attachment
Scope
This statement is aimed to present the proposed procedures that shall be adopted to apply the
specialist material for concrete protection on the internal surfaces as specified.
References
Collection sump 70-TB-201                                           Utilities East
Collection sump 70-TB-202                                           Ethylene
Collection sump 70-TB-203                                           Utilities East
Collection sump 70-TB-205                                           Utilities South
Drawings
Specifications
Master seal 550-product data sheet
Definitions
PSM                      Project Site Manager
CSM                      Construction Manager
CS                       Construction Superintendent
FM                       Foreman
QC                       Quality Control
Responsibilities
PSM shall control the overall operations
CM shall arrange the resources required accordingly
CS shall control, monitor and direct the FM and workforce for the operations
FM shall execute the operations deploying the workforce
QC shall inspect all the operations according to the specifications
EPC Contractor shall conduct surveillance
Safety
Prior to the commencement of work, the labour force shall receive the tool box talk on the
Project Site Safety requirements. Any process that is adopted which may have a particular
Safety risk, shall be assessed to the requirement for Site conditions and be taken care of.
Scaffolding shall be erected to afford access to the working personnel according to the project
requirements. Hand rails ladders and the toe boards shall be fitted and inspected prior to use.
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              107 of



During mixing and application of master seal 550, personnel protective equipment shall be
used i.e. overalls, goggles, gloves (to avoid material contact to eyes, mouth and skin)
Material storage / disposal of used containers / waste material
Materials shall be stored out of direct sunlight clear of ground and protected from rainfall.
Used containers shall be collected and disposed off as per project requirements.
Materials
Coating, Masterseal 550
Master seal 550 is a two component acrylic modified cementitious coating that requires only
site mixing to form an ideal product to waterproof and resurface concrete, masonry and most
other construction materials. Simply applied by stiff brush, roller or trowel it forms a waterproof,
flexible coating providing an effective barrier to waterborne salts and atmospheric gases.
Method
The method involves the following sequences in general.
Surface preparation
Mixing
Application
Details
All grease, oil, dust, residual curing compound, mould release agent or other contaminants,
which could impair adhesion, shall be removed from the surface by degreasing and washing.
The whole surface to be coated shall be cleaned using water jetting and visually inspected to
ensure that the roughness does not exceed grade 80 sandpaper.
All the holes, voids, depressions, spalls etc., shall be filled with Masterseal 550 mixed to a
trowel consistency ,scraped lightly into the surface, allowed to dry and later roughened by
hand wire brush on the small areas and gently water jetted on the larger areas.
The filled areas shall be visually inspected to ensure that the correct mechanical key is
achieved.
Mixing
Master seal is supplied in the pre measured units and shall be mixed on site using clean
containers. The powder shall be slowly added to the liquid component and agitated / mixed
for 2 minutes by using a slow speed hand power drill fitted with a suitable paddle attachment,
until a homogeneous lump free consistency is obtained.
The mix quantity shall be such that it could be consumed in one hour during application without
allowing any retempering with water.
Application
Coverage 1.8 Kg / sqm at 1 mm thickness
The coating shall be 1 mm thick applied in one coat
In hot weather the surface to be coated shall be shaded from direct sunlight.
The areas to be coated shall be saturated with fresh and clean water.
The prepared and the saturated surface shall be inspected by Civil Contractor QC followed by
EPC Contractor approval
The mixed material shall be applied while the surface is visibly damp without standing water
using short stiff brush or roller. (Roller shall be used in major / large areas)

Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              108 of



The evenness and the thickness of the applied coating shall be regularly checked during
application while the material is still wet.
The materials shall be allowed to dry and visually inspected
Civil Contractor QC inspection shall be conducted followed by EPC Contractor approval
Any missed areas shall be saturated and then touched up.
Equipment
Water tanker with water jetting arrangement
Hard brushes for minor areas
Clean container
Slow speed drill with paddle attachment
Stiff brush / Roller
Attachment
Masterseal 550 Data sheet and statement
#48

Dewatering for the 84” GRE                                                                                                               pair                        line
parallel to
Corniche road    east west
 Top
Index
Scope
Reference documents
Definitions
Responsibilities
Safety
Method
Equipment
Attachment
Scope
The statement is aimed to present the proposed procedures to be adopted to keep the
proceeding excavations, for the route respecting pair of 84 “ GRE pipe lines to be laid in, dry
and free of inflowing water
References
Specifications Water Control / Dewatering Plan , Dewatering and Drainage
Excavation Safety Plan
Excavation & Backfilling for Underground structures.
 Definitions
PSM          Project Site Manager.
CM           Construction Manager.
CS           Construction Superintendent
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              109 of



FM            Foreman
Responsibilities
CM shall plan and resource the trench excavation and backfilling activity, in accordance with
this method statement.
The Construction Foreman shall monitor these activities directing the workforce as necessary.
EPC Contractor shall control the activities.
Safety
Appropriate means regarding safety shall be provided to the requirements .
Round the clock watch and ward shall be maintained for the plants and the Equipment
Safety standard barriers posted with warning tags shall be installed on both the sides of the
excavations covering the well point systems also
Night indicator lights shall be provided according to the provisions of safety
Access ladders shall be provided every 8 m intervals
The safety inspector shall visit the site every day in the morning and the after noon to check
whether the safety systems work to the requirement or else the corrective measures be
applied.
The water logged area shall not be allowed for the workers in general to acceed crossing the existing
fence except, if so required , for the purpose of laying out hoses over used plies to be routed in to
reach the proposed sumps for the pumped water disposal.
METHOD
Ref      Attached Drawing and Sketches
The North South excavation has already been carried out to the intersection of the proposed
line and the Corniche Road as indicated by point at „S‟
On the proposed route of the lines i.e on the North of the road exist various services at a
distance 4 m to 8 m at a depth of 2 to 3 m from the existing road level running along
eitherside of the intersection i.e East and West        as shown on the attached sketch as
locations marked A to H for the exposed inspection pits
The existing uneven ground level on the proposed area is 1.8 m average lower than the road
level and the water is available at 2 m from the road level but fluctuates rapidly depending on
the tides.
The GRE pipe 2200 mm dia pair shall be laid at a bedding of not less than 4000 mm to 4500
mm from the road surface .Since the drawing shows the natural ground level 3.4 m , a 2.4
m depth is required to be excavated , while water level is shown at 2.15m level, water has to
be bailed out upto 0-0 level requiring a 2m massive dewatering along the entire route
commencing from the intersection at point „S„ to the terminal point at „T‟.
The existing services shall be protected by the necessary measures according to the
statutory regulations and the specifications prior to the excavation commencement for which
an inquiry be conducted with the relevant Statutory Organizations / Client
Since this massive earth work is to be carried out in full to cover a length of       1200 m or
more , dewatering shall be carried out accordingly by the standard Well Point System to be
installed on both sides of the proposed route at a depth of minimum 3 m from the existing
ground levels at the locations shown on the sketch / drawing and disposed off through
the hoses into the proposed sumps to be located at varying distances from 100 to 200 m off
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              110 of



the road berm by the use of booster pumps installed next to the intermediate water tanks, so
as not to allow the disposed water to flow back into the well point systems.
For the route part besides the box culvert (under construction) leading to the pipelines West
end after running beneath the overhead conveyors, the disposal may be made into the culvert
manholes as being done by M / S ARCHIRODIN CONSTRUCTION OVERSEAS for that the
matter was casually discussed with the supervisor on site Mr BADRI who expressed no
concern should the water be discharged that way.
Anyway should this option does not work, the disposal shall be carried on to the proposed
sumps as shown since in the vicinity of the Sulpha Plant Building area further sumps to form
may not be allowed.
The sumps shall be located as shown on the drawing / sketch near the embankment north
/ south side , for south after jumping over the bund, whatever course be feasible. On the
south of the embankment side the existing levels are low lying. A total of 8 to 10 sumps shall
be needed be formed.
The sump pits to receive the disposed water shall be filled with 75 mm clean aggregate prior
to the disposal is commenced
The Well Points on both sides shall be installed in sections of 100 m average for each Sykes
Pump catchment and the disposal be effected to as shown by boosting.
It shall take a duration of around 60 days to carry out the excavation,bedding, laying
pipes and the backfill,the system / s have to be kept working till these operations are over .
Equipment / plants
Well point system
Plants and equipment requirement

S#          ITEM DESCRIPTION                                                         UNIT           QUANTITY                    REMARK
1           Length of the proposed route                                             m              2400                        2 x 1200 m
2           Length of the well point system                                          m              2400                        2 x 1200 m
3           150mm dia Headers average 5 m or                                         each           480                         6 points in each
            so long
4           50 mm dia Well points 3 m long                                           each           2880                        Filterable
5           50 mm dia Well points /        Headers                                   each           2880                        6 connections each
            Flexible connections                                                                                                header
6           Sykes / Miller pumps with suction and                                    each           24                          1 pump / 100 well
            delivery heads                                                                                                      points
7           Intermediate water tanks (open top)                                      each           6                           1 tank for 4 Sykes
            3 cum capacity                                                                                                      pumps
8           Booster pumps 5 bhp with compatible                                      each           6                           1 booster pump for 4
            fittings for tanks connections                                                                                      Sykes pumps
9           150 mm dia hose pipe to suit the pump                                    m              500                         Delivery upto the open
            inlets and outlets with suction and                                                                                 water tanks
            disposal / delivery heads
10          75 mm dia disposal hose to suit the                                      m              1500                        Disposal from open
            water tank outlets                                                                                                  water tanks to the
                                                                                                                                proposed sumps
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              111 of



11          150 mm steel sleeve pipe for under m                                                    50                          To be installed for the
            ground use                                                                                                          incoming crossings
12          Drilling Rig with adjustable Auger each                                                 1                           For drilling well point
            attachment for 50 mm dia Well Points                                                                                bores
13          All other compatible fittings and
            miscellaneous items for the whole
            assembly not covered in above

ATTACHMENT
Drawing showing the well point system installation layouts and section
Typical details of the system indicative only
#49

Ceramic wall tiles fixing
Top
(INTERNAL)
Administration building
Index
Scope
Reference documents
Definitions
Responsibilities
Safety
Method
Equipment
SCOPE
This statement is aimed to present the proposed procedures to be adopted to fix the
Ceramic wall tiles by bedding with an approved adhesive on one coat plaster applied
according to the specification with the pre spatterdash treatment except on metal lathing where
2 coats are permitted with wood float finish, uniformly as thick as possible and not less than 8
mm or more than 13 mm
References
Specification
Safety
The work force shall receive every day prior to the commencement of any activity a Tool Box
talk regarding operational safety according to the project requirements in addition to the use of
personal protective equipment..
Specifically the personnel engaged on the tiling items shall use masks to prevent inhale the
grout or the adhesive smell.


Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              112 of



In the rooms where proper ventilation or the sunlight is not available, electric lights shall be
provided with due care regarding protection from the electric wires ,the distribution board and
the other fixtures etc.,
In hot weather standing upright fans shall be provided at the work areas.
The work area shall be closed to general workers on other parts and opened only after the tiles
have been finally cleaned as well the space cleared of electrical fittings.
Definitions
PSM                      Project Site Manager
CSM                      Construction Manager
CS                       Construction Superintendent
FM                       Foreman
QC                       Quality Control
Responsibilities
PSM shall control the overall operations
CM shall arrange the resources required accordingly
CS shall control, monitor and direct the FM and workforce for the operations
FM shall execute the operations deploying the workforce
QC shall inspect all the operations according to the specifications
EPC Contractor shall conduct surveillance
Material
Glazed Tile size specified 108 x 108 mm
Setting material (ultra set polyurethane adhesive ) recommended by manufacturer
Cushion edges
Rounded external corners
Head Jamb and Cill trim shapes
Wain scot cap Surface bullnose or bull nose cap
External corners Bullnose shapes or as specified
Internal corners Field butted square
Grouting material Water proof epoxy tiling grout with antifungicide additive
(Commercial white sanded latex portland cement type)
Method
Mesh reinforcement shall be incorporated in the plaster where
1 The structure is out of line and the thickness of the plaster exceeds 13 mm
2 The plaster is to be applied over different structural materials
3 The surfaces of the structural wall shall be subject to excessive movement .e.g., light
    weight concrete block of all types
Examination
The strata to receive the tiles shall be examined closely to ascertain that the moisture content
are within limits to allow the fixing operation
Where the tiling is to be bedded in a thin bed adhesive, the trueness of the plaster shall be
such that when tested with a 3 m straight edge no gap exceeds 3 mm


Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              113 of



Where the gap lies between 3 and 6 mm, if the walls are out of plumb by not more than 6 mm,
a thick bed adhesive shall be applied in preferance to cutting the defective areas and making
good
Deviation from true vertical or plumb in the surface of plastering exceeding 6 mm shall be
made good
Thin bed adhesive shall not be used for fixing tiles with backs incorporating deep keys or frogs
for which thick - bed adhesives must be used
Civil Contractor inspection followed by EPC Contractor approval
The tiles shall be set out before the work commences so that cut tiles be kept to a minimum
and where they do occur be as large as possible
Joints shall be horizontal and vertical, with horizontal joints aligning in walls that adjoin or be
adjacent
The tiles shall be neatly and accurately cut to close fit where necessary at abutments and
around outlets, pipes and the like
The tiles shall be extended into recesses, under equipment and fixtures to form a complete
covering without interruptions as well as terminated neatly at obstructions, edges or / and
corners keeping the on going pattern or joint alignment. The tiles shall fit closely to the
electrical outlets and fixtures allowing plates, collars, covers etc., overlap the tiles.
Movement joints not less than 6 mm shall be provided:
At all internal vertical corners
At all angles with structural walls and ceilings
To form bays not greater than 3000x4500 mm
Over all structural movement joints:
The joints shall be carried through the plastering to the structural wall, partially filled with an
approved joint filler and finished flush with an approved sealant recommended by the
manufacturer for the relevant situations.
Glazed edge tiles shall be used at the exposed edges.
The tiles shall be fixed in position prior to the adhesive gets dried for that it shall be prepared
and applied on a small area not exceeding 1m x 1m at a time with a trowel to dry plaster
surface in a manner recommended by the manufacturer followed by the tiles pressed firmly
into with a twisting / sliding action tapping firmly and cleaned as soon as the bedding be
completed.
The finished surface of the tile shall be firm and true such that when checked with a 3 m
straight edge, no gap exceeds 3 mm
Civil Contractor inspection followed by EPC Contractor approval
The joints shall be grouted well to completely fill in as well as appear flush after the adhesive
has set and not less than 48 hours post fixing. Surplus grout shall be cleaned off from the tiles
surfaces as neatly as possible as the work proceeds using a damp cloth and the joints tooled
smooth.
The grout haze shall be removed according to the manufacturer‟s instructions for the use of
acid and chemical cleaners
The tile work shall be rinsed thoroughly with clean water prior to and post using chemical
cleaners followed by polishing with soft cloth.

Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              114 of



Civil Contractor inspection followed by EPC Contractor approval
Equipment
Tile cutter
Attachment
Approved ITP Form

#50


Bedding and gravel filling beneath 60 “ dia pipe
cooling water pipe
Top
Index
Scope
Reference documents
Definitions
Responsibilities
Safety
Method
Equipment
Attachment
Scope
This statement is aimed to propose the procedures to be adopted for the execution of bedding and the
sub strata gravel filling with the provision to prohibit the fine soil particles to migrate to the bedding
beneath the pipe where the water table is met at the bedding level making the compaction and the
density test unsustainable
Reference documents
Drawing
Specification. Excavation & Backfilling for Underground structures.
Definitions
PSM            Project Site Manager.
CM             Construction Manager.
CS             Construction Superintendent
FM             Foreman
Responsibilities
CM shall plan and resource the trench excavation and backfilling activity, in accordance with
this method statement.
The Construction Foreman shall monitor these activities, directing the workforce as necessary.
EPC Contractor shall control the service laying activities.

Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              115 of




Safety
Prior to the commencement of any activity, the labour force shall receive a tool box talk on the
project site safety requirements. Any process that is adopted having a particular safety risk
shall be assessed and addressed as required.
A competent inspector shall inspect the trench daily to assess the safety measures adopted
as well as after every rainstorm. If required, the shoring shall be provided to prevent the
caving in. In case of the trench depth being more than 1200 mm, adequate means of exit such
as ladders or steps shall be provided and located no more than 8 m of lateral travel.
Barricades, markers and the night lights etc., shall be arranged as required.
Safety
Method
COOLING WATER PIPE LINE 60 “ DIA PIPE BEDDING AND GRAVEL FILLING
The attached sketch shows the proposed bedding and sub strata gravel filling wrapped by
Geotextile.
The excavation shall be carried out upto the formation level plus another 200 mm for crushed
gravel filling as shown .
The Geotextile TERRAM membrane shall be laid on the prepared substrata as shown.
A well packed 200 mm thick crushed gravel filling shall be carried out on apprx.3000 mm
wide base.
The Geotextile TERRAM membrane shall be continued over the prepared crushed gravel
filled formation level surface making gravels wrapped fully allowing no fine soil particles enter
the strata.
Over this wrapped strata a 150 mm thick sand bedding shall be carried out duly compacted
according to the requirement of the specifications.
After these operations are over and the inspection done, 60 “ dia pipe shall be laid according
to the requirement
Equipment
Excavator
Compactor
Attachment
Sketch
#51
External concrete protection
Administration building
Top

Index
Scope
Reference documents
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              116 of



Definitions
Responsibilities
Safety
Storage
Material
Method
Equipment
Attachment
Scope
This statement is aimed to propose the procedures to be adopted to form a protection coating
on the external concrete surface to be cladded with the Glass Reinforced Concrete elements.
References
Drawing
Specification
above ground concrete protection.

Definitions
PSM                      Project Site Manager
CSM                      Construction Manager
CS                       Construction Superintendent
FM                       Foreman
QC                       Quality Control
Responsibilities
PSM shall control the overall operations
CM shall arrange the resources required accordingly
CS shall control, monitor and direct the FM and workforce for the operations
FM shall execute the operations deploying the workforce
QC shall inspect all the operations according to the specifications
EPC Contractor shall conduct surveillance
Safety
Prior to the commencement of any activity, the labour force shall receive a toolbox talk relevant
to the operation concerned on the project site safety requirements. Any process that is
adopted having a particular safety risk shall be assessed and addressed as required.
Only tagged scaffolding comprising all the guard rails foot rails etc.,shall be used for the work
at heights according to safety requirements.
The use shall be made in well-ventilated area and avoid inhalation.
The personnel shall use protective clothing, gloves eye protection glasses, masks etc., for to
avoid skin contact. Plenty of clean water shall be available all the time.
Medical attention shall be available all time to treat the adverse effects.
Transportation shall be available to move the effected personnel to the hospital should the
circumstances so require.

Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              117 of



Storage
The material shall be stored under cover out of direct sunlight and protected from temperature
extremes. Product shelf life is 12 months subject to proper storage
Care shall be taken during use and storage to avoid contact with eyes, mouth, skin and
foodstuffs. The containers shall be resealed after use. Immediate medical attention shall be
called for in case of any adverse effect to the personnel handling the product
Damaged tins shall be disposed off according to the state regulations.
Material
Master Builder Technology Product
Masterseal 300H - an acrylic based, elastomeric decorative, flexible, anti-carbonation and
waterproof protective coating designed for the protection of concrete structures against
carbonation and chloride ingress.
Masterseal 181S- primer system
Masterseal 300 H filler
Method
This application involves the following sequences
Cleaning and making up the surface
Priming the surface
Coating the surface
Details
Preparation
All surfaces shall be free from oil, grease, friable matters and curing compound.
The surfaces shall be cleaned from dust / sand using compressed air.
Arrises shall be rounded off and the protrusions ground so that the resulting surfaces appear
smooth.
The surfaces shall be brush primed with Masterkure 181S and subsequently Masterseal 300H
mixed with Masterseal 300 H filler applied as a scrape coat over blow holes and depressions.
The primed surface shall be allowed to dry tack free for a minimum duration of 2 hours before
applying Masterseal 300H coating.
Application
Masterseal 300 H shall be applied directly from the containers using a brush or roller @ 0.8
litre per sqm surface coverage to achieve a continuous coating
The continuous coating may be achieved in 1 or 2 coats of application
The coating shall be protected from the rain and humidity for 24 hours / until it dries out
using polythene sheets keeping off the area.
The coating shall be applied when the humidity is less than 90 %
The coating shall not be applied in the dusty weather conditions
No post application curing is required
The areas to be coated shall be protected from direct sunlight by shading in the hot weather
conditions and the ambient temperature be more than 5 degree Celsius.
Equipment
Brush
Roller
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              118 of




Attachment
MBT Statement
#52

Above ground concrete protection
Using masterseal 300 h
Top

Index
Scope
Reference documents
Safety
Method
Equipment
Attachment
Scope
This statement is aimed to propose the procedures to be adopted to apply protection coating
on above ground concrete surfaces.
References
Specification
above ground concrete protection.
MAR -Material Approval for 181 S and 300H
Safety
Prior to the commencement of any activity, the labour force shall receive a toolbox talk relevant
to the operation concerned on the project site safety requirements. STARRT Card shall be
used. Necessary measures shall be applied to any activity involving safety risk.
Only tagged scaffolding with guardrails, foot rails etc., shall be used to afford access to high
locations. Material shall be used in well-ventilated area and inhalation avoided.
Personnel shall use protective clothing, gloves, eye protection, masks etc .to avoid skin
contact. Plenty of clean water shall be made available.
Safety Supervision
A competent inspector shall visit the area daily to assess the safety measures adopted. Any
snag observed during his visit, shall be notified to the supervisor present who immediately act
to bring the safety measures to an acceptable standard
Material
Master Builder Technology Product
Masterseal 300H - an acrylic based, elastomeric decorative, flexible, anti-carbonation and
waterproof protective coating designed for the protection of concrete structures against
carbonation and chloride ingress.
Masterseal 181S- primer system

Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              119 of



Masterseal 300 H filler
Storage
The material shall be stored under cover out of direct sunlight and protected from temperature
extremes. The containers shall be resealed after use. Damaged tins shall be disposed off
according to the state regulations.
Method
Surface Preparation
All surfaces shall be free from oil, grease, friable matters and curing compound.
Sweep blasting shall be used when necessary to obtain an acceptable surface for coating
otherwise the surfaces shall be cleaned from dust / sand using compressed air.
Arrises shall be rounded off and the protrusions ground so that the resulting surfaces appear
smooth.
Primer
The surfaces shall be brush primed with Masterkure 181S and allowed to dry for 2 hours
Subsequently Masterseal 300H mixed with Masterseal 300 H filler applied as a scrape coat
over blowholes and depressions and allowed to dry.
Application
Masterseal 300 H shall be applied directly from the containers using a brush or roller @ a
minimum of 0.8 litre per sqm surface coverage to achieve a continuous coating
Continuous coating may be achieved in 1 or 2 coats of application
The coating shall not be applied in the dusty weather conditions
No post application curing is required
Equipment
Brush
Roller
Attachment
MBT Statement
#53

Above ground concrete protection
Using masterseal 300 h
  Top

Index
Scope
Reference documents
Safety
Method
Equipment
Attachment

Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              120 of




Scope
This statement is aimed to propose the procedures to be adopted to apply protection coating
on above ground concrete surfaces.
References
Specification
above ground concrete protection.
MAR -Material Approval for 181 S and 300H
Safety
Prior to the commencement of any activity, the labour force shall receive a toolbox talk relevant
to the operation concerned on the project site safety requirements. STARRT Card shall be
used. Necessary measures shall be applied to any activity involving safety risk.
Only tagged scaffolding with guardrails, foot rails etc., shall be used to afford access to high
locations. Material shall be used in well-ventilated area and inhalation avoided.
Personnel shall use protective clothing, gloves, eye protection, masks etc .to avoid skin
contact. Plenty of clean water shall be made available.
Safety Supervision
A competent inspector shall visit the area daily to assess the safety measures adopted. Any
snag observed during his visit, shall be notified to the supervisor present who immediately act
to bring the safety measures to an acceptable standard
Material
Master Builder Technology Product
Masterseal 300H - an acrylic based, elastomeric decorative, flexible, anti-carbonation and
waterproof protective coating designed for the protection of concrete structures against
carbonation and chloride ingress.
Masterseal 181S- primer system
Masterseal 300 H filler
Storage
The material shall be stored under cover out of direct sunlight and protected from temperature
extremes. The containers shall be resealed after use. Damaged tins shall be disposed off
according to the state regulations.
Method
The system shall only be applied to surfaces that have been passed as being ready to receive
them. All necessary repairs to the concrete surface shall have been carried out and relevant
QC documentation completed.
All surfaces shall be free from oil, grease, friable matters and curing compound.
Sweep blasting shall be used to obtain an acceptable surface for coating and the surfaces
shall be cleaned from dust / sand using compressed air.
Primer
The surfaces shall be brush primed with Masterkure 181S and allowed to dry for 2 hours
Subsequently Masterseal 300H mixed with Masterseal 300 H filler applied as a scrape coat
and allowed to dry.


Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              121 of



Application
Masterseal 300 H shall be applied directly from the containers using a brush or roller @ a
minimum of 0.8 litre per sqm surface coverage to achieve a continuous coating
Continuous coating may be achieved in 2 coats of application (minimum)
The coating shall not be applied in the dusty weather conditions
No post application curing is required
Equipment
Brush
Roller
Attachment
MBT Statement
#54

Hand excavation to install
Telephone ducts between box no. 20 to
telecom centre
Top
Index
Scope
Reference documents
Definitions
Responsibilities
Safety
Method
Equipment
Attachment
Scope
This statement is aimed to propose the procedures to be adopted to carry out the laying in
2 No. 4 “ dia PVC ducts for telecommunication cables over the existing ducts between box No.
20 to telecom centre.
References
Drawing Nos.
Specification. Excavation & Backfilling for Underground structures.
Definitions
PSM            Project Site Manager.
CM             Construction Manager.
CS             Construction Superintendent
FM             Foreman

Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
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Responsibilities
CM shall plan and resource the trench excavation and backfilling activity, in accordance with
this method statement.
The Construction superintendent shall control and monitor the operations directing the
construction Foreman
The Construction Foreman shall execute these activities directing the workforce as necessary.
EPC Contractor shall control the activities.
Safety
Prior to the commencement of any activity, the labour force shall receive a toolbox talk on the
project site safety requirements. Any process that is adopted having a particular safety risk
shall be assessed and addressed as required.
A competent inspector shall inspect the trench daily to assess the safety measures adopted as
well as after every rainstorm. If required, the shoring shall be provided to prevent the caving
in. In case of the trench depth being more than 1200 mm, adequate means of exit such as
ladders or steps shall be provided and located no more than 8 m of lateral travel. Barricades,
markers and the night-lights etc., shall be arranged as required.
Status
The site is located at the police station where 2 no. manholes MH2 and MH3 exist
The manholes centre-to-centre distance is 141 m. The proposed section to be excavated is
500mm wide and 1000 mm deep. Additional / spare 2 nos. PVC ducts 4 “ dia are to be
provided above the existing ducts
The access road to the police station is wearing asphalt course
From manhole no. 3 to no. 2 i.e. 141 m is running under the police station car park and the
access road. The main portion of the line in the middle as shown is access road and the
parking facility for the police station
The internal portion of the line from man hole no. 2 to the internal Telecom Vault is also
running beneath the interlocking blocks paving after crossing under the fence wall
Method
The work shall involve the following operational procedures.
Between man hole No. 3 and No. 2.
Remove the interlocking blocks
Road cutting at the police station entrance across 500 mm wide or as required
Bridge the gap at the road cut using steel plates to facilitate the smooth traffic plying
Manual excavation of the trench in the entire 141 m length
Sand bedding 75 mm
Install 2 nos. 100 mm dia pipe ducts
Sand filling over the ducts 75 mm
Backfilling as specified
Refixing the interlocking tiles
Making good the access road
Removing the steel plates
Between the manhole No. 2 and the internal telecom vault
Removing the interlocking blocks
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
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                                                                                                                                              123 of



Manual excavation of the trench to the existing ducts from the manhole No.2 to the internal
vault crossing below the fence wall
Sand filling 75 mm thick below the proposed duct
Laying ducts
Filling 75 mm thick sand over the laid ducts
Entering cable way
Making good the entry
Backfilling as specified
Refixing the interlocking blocks to the pattern
Clearing the site
Details
External
The existing interlocking paving tiles shall be removed to a safer location from the required
work area and stacked properly
The access road shall be cut across to the required level exposing the existing ducts and the
bridging steel plates be laid over completely to facilitate the car access
The manual excavation shall be carried out in the entire length of 141 m to the given sectional
dimensions upto the existing ducts as shown
After the excavation to the required depth is completed, a 75 mm thick layer of sand shall be
filled in on the existing ducts to receive 2 nos. 4 “ dia new ducts which be placed and further
covered with another 75 mm thick sand layer
After the sand is filled in, the backfilling shall be carried out according to the project
specifications upto the bottom of the interlocking blocks to be refixed
After the backfilling is completed, the interlocking blocks shall be refixed to the same location
or the pattern, which existed before these were removed.
The backfilling shall be done in the road cut part upto the concrete bottom and asphalt laid
over
After the whole backfilling is over, the effected access road shall be made good by asphalt
laying on concrete base
Internal
The interlocking blocks shall be removed from the proposed marked route and stacked well
and safe to be reused
The excavation shall be carried out on the entire length from the fence to the existing vault
The excavation shall be carried out from the manhole nos. 2 to the inside of the wall
penetrating beneath
The whole route of the existing ducts shall be exposed
Sand shall be filled in 75 mm thickness over the existing ducts
Spare ducts 2 nos shall be laid over the sand filling over the existing ducts
Further sand filling 75 mm thick shall be carried out to cover the new ducts and the backfilling
be commenced to the bottom of the existing interlocking pavement according to the
specifications
After the backfilling is over, the interlocking blocks shall be refixed to the existing pattern and
the effected wall portion be repaired to the extent of damage if any

Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              124 of



The external portion from the wall to the manhole shall also be sand filled and backfilled
according to the details
The whole work shall be approved
Equipment
Jackhammer
Compressor
Attachment
Sketch
#55

Backfilling of the west side of the quench tower
foundation – (rib)
 Top
Index
Scope
Reference documents
Existing Windows Section as per drawing
Reasons for Proposal
Details of New proposal and Location change in Placement
Method
Equipment
Attachment
Scope
This statement is aimed to propose the procedures to be adopted for the construction of                                                                                       the
west direction extended part of the design foundation / Cantilever rib.
References
Drawing
The revised IFC drawing was received after the completion of the blinding concrete and                                                                                        the
Rebar binding works.
Definitions
PSM Project Site Manager.
CM      Construction Manager.
CS       Construction Superintendent
FM       Foreman
Responsibilities
CM shall plan and resource the activities in accordance with this method statement.
The Construction Superintendent shall control and monitor the operations directing                                                                                            the
construction Foreman.
Foreman shall execute and assist monitor these activities directing the workforce                                                                                              as
necessary.
EPC Contractor shall control the activities.

Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              125 of



Safety
The workforce shall receive every day before the commencement of any activity a Tool Box
talk relevant to the operation according to the project requirements. All the safety measures
shall be arranged according to the operational requirement.
Method
The extended part shall be constructed to the following sequences.
The concrete shall be poured to the preparatory works carried out on site.
The deshuttering shall be done after 14 days.
Application of the membrane to the underside / soffit of the slab.
Backfilling the underside space by the lean mix PBFC 20 grade concrete.
Details
Since all the preparatory works such as the bending and binding of the reinforcement,
centering and shuttering of form work, propping etc., and all the relevant activities have been
carried out to the design requirement per previous revision and according to the project
specifications, the concrete shall be poured to the works done.
After the completion of the pour and the sequential curing and a lapse of 14 days, the forms
shall be struck from the underside of the slab / soffit
The formed surface shall be applied with the protective concrete membrane as specified and
shown on the sketch
The space left between the soffit and the prepared ground shall be prepared for the concrete
filling by erecting the formwork in the letter box style
The forms shall be fabricated according to the following descriptions
Bottom panel of 600 mm height shall be erected around
Top panel of 200 mm shall be prepared in letter box style to allow the pour of the concrete
The top panel post pour shutters shall be made ready before the commencement of the
concrete
Immediately after the pour reaches to the brims / soffit level
The top panels shall be placed in position to close all the external surface and supported to the
requirement
The forms shall be struck as per the project specification
Equipment
Concrete Pump
Concrete Transit Mixers

Attachment
Sketch
#56

Excavation Cooling water outfall chamber
Top
Index
Scope
Reference documents
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              126 of



Definitions
Responsibilities
Safety
Method Equipment
Attachment
Scope
This statement is aimed to present the proposed procedures to be adopted to carry out the
excavation for the foundation in respect of the Cooling Water Outfall Chamber.
References
Drawing
Specification Excavation & Backfilling for Underground structures.
Definitions
PSM Project Site Manager.
CM       Construction Manager.
CS       Construction Superintendent
FM       Foreman
Responsibilities
CM shall plan and resource the excavation activity in accordance with this method statement.
The Construction Superintendent shall control and superintend and monitor the operations
directing the Foreman as required.
The Construction Foreman shall execute these activities, deploying the workforce on the job as
necessary.
EPC Contractor shall do surveillance on the operations.

Safety
Prior to the commencement of any activity, the labour force shall receive a tool box talk on the
project site safety requirements. Any process that is adopted having a particular safety risk
shall be assessed and addressed according to the project safety requirements.
A competent inspector shall inspect the excavated area daily as well as after every rainstorm
to assess the safety measures adopted. If required, the shoring shall be provided to prevent
the caving in. In case of the trench depth being more than 1200 mm, adequate means of exit
such as ladders or steps shall be provided and located no more than 8 m of lateral travel.
Barricades, markers and the night-lights etc., shall be arranged as required.
Design Status
The centre lines of the proposed structure and the coordinates meet at
N (Typ) and E (Typ)
The plan size of the chamber is 10.025 m x 7.2 m
The excavation has to be carried out to the +2.3 m level from RGL +10.500 i.e a depth of 7.8
m shall be excavated
Method
The excavation shall be carried out to the following sequences
Setting out the lines
Barricading the area
Excavation in stages as shown on sketch
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              127 of



Details
Attached sketch
To start with, a surveyor shall set out the site for the excavation
to the exact lines and coordinates references.
After the setting out, the excavation lines shall be marked 4750 mm away from the proposed
external faces of the structure as shown on the sketch.
The excavation shall be carried out to the details shown on the sketch in 5 steps of size 750
mm tread and 1500mm riser and the bottom step of 675 mm riser.
The size of the lowest level excavation shall be 120025 x 9200 mm and that of the top 19525 x
16700 mm.
The excavation shall be started from one end and the top 750 mm deep be completed
The access shall be ramped for the equipment to enter.
The excavation shall be carried out in strips of 750 mm depth until the whole earth mass is
taken out.
The excavated earth shall be transported to the stockpiles immediately keeping the site tidy.

Equipment
Excavator
Dumper
Attachment
Sketch
#57

Drilling of holes on
Pipe rack & structures on site
Top
Index
Scope
Reference documents
Definitions
Responsibilities
Safety
Method
Equipment
Scope
The purpose of this Method Statement is to define the sequence and methodology that shall
be implemented for the drilling of holes on structural steel members that have been erected
and which requires the drilling of holes due to manufacturing error in location or design change
after the beams have been primed or finished coated.
 Reference Documents
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              128 of



Specification Steel Structure Fabrication
Specification Painting
Specification Galvanizing
Specification Structural Steel Erection
ANSI A 10.13 Safety Requirements for Steel Erection
Relevant Drawings

Definitions
CM             Construction Manager.
CS             Construction Superintendent
FM             Foreman
Responsibilities
CM shall plan and resource the drilling of holes, in accordance with this method statement.
The Construction Supertindent shall monitor these activities, directing the workforce as
necessary.
The Erection Foreman shall control the workforce ensuring the full implementation of this
method statement including safety measures.
Safety
Prior to the commencement of any activity, the labour force shall receive a tool box talk on the
project site safety requirements. Any process that is adopted having a particular safety risk
shall be assessed and addressed as required.
The use of cranes or man lifts shall be assessed and all safety regulations enforced.
Men working at heights shall be equipped with the required personal safety equipment.
Method
The new location of the hole centres on the specific member item shall be marked as per the
details on the drawing or drawing revision.
Using a drilling machine, preferably a magnetic base drilling machine, a pilot hole of size 8mm
or 10mm diameter shall be initially drilled. These holes shall be subsequently drilled to the
specified diameter.
The area around the holes shall be cleaned, burrs removed and edges rounded off. This shall
be effected by either using emery paper or grinding wheel.
The bare surfaces is made dust free and cold galvanizing applied as a coat with „Jotun Barrier
86” , a two pack zinc-rich epoxy primer .
Allow about 4 Hours for drying.
Make necessary touch-ups using the same grade, colour which were used to paint the
structure-prime coat and the top coat if necessary.
Equipment
Drilling machine
Man lift
Scaffolding if required
Grinding machine
#58
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              129 of




Site office establishment
Top
Index
Scope
Reference documents
Definitions
Responsibilities
Safety
Method
Equipment
Attachment
Scope
The purpose of this method statement, is to define the procedure that shall be adopted for the
establishment of the site office.
Reference documents
Approved Site office layout and details drawings.
Definitions
EPC Contractor
Civil Contractor .
PSM Project Site Manager.
CS     Construction Superintendent.
IS      Infrastructure Superintendent.
ST     Survey team.
Responsibilities
The PSM shall ensure the establishment of the site office complex is in accordance with the
drawings and agreed specifications.
The Construction Superintendent shall coordinate and supervise the day to day activities,
along with the Foremen and Survey Team.
Safety
The Safety Officer shall monitor the daily activities, advising and implementing all safety
procedures.
Method
The site shall be graded and compacted to the levels indicated upon the approved grading
drawings. The ST shall check the final grades. A record drawing of the final grades shall be
produced.
The ST, using approved drawings, shall set out the relevant issues such as service trenches
and foundations.
Services:
Service trenches relating to the site office complex, for the drainage, water, electric and fire
water, shall be set out.


Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
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                                                                                                                                              130 of



Working to levels, a mechanical excavator shall excavate the trenches. Excavated material
shall be re-used for backfilling when the services have been installed. Surplus material shall be
removed from site. The services may share common trenches where appropriate.
The drainage pipes shall be installed to grade. Manholes shall be placed at locations indicated
upon the site office complex drainage drawings.
Sewage holding tanks shall be located as per drawing. A steel tank shall be utilized for water
storage. The tank shall be backfilled as appropriate.
Draw pits and chambers for cabling shall be located in a similar manner. All service trenches
shall receive appropriate sand bedding and surround, plus warning tape for cabling shall be
provided. Where any services shall cross an area that shall be trafficked, the service shall be
ducted or / and protected with concrete surround as appropriate.
Foundations:
For the pre-engineered office units, the foundation layout drawing that indicates the precast
concrete block foundation locations, shall be utilized for the setting out. The precast concrete
foundation blocks, shall be placed upon the pre graded ground. The pre-engineered office
units, shall be off loaded from the delivery wagon, direct onto these blocks. Shim plates shall
be used between the precast concrete block and the unit chassis where necessary.
Power Supply:
The relevant pre-engineered sections shall be sealed. The relevant utilities that require
connection shall be connected. The appropriate electrical power supply and distribution
network shall be provided and commissioned as per approved drawings and schematics. The
appropriate checklist shall be utilized.
Telephone Service.
Etisalet shall provide the service to the designate locations within the building. The internal
distribution system shall be installed as per approved scheme.
Infra structure:
Access roads to the site office shall be constructed according to the layout drawing.
Footpaths around the site office shall be constructed as per drawing.
Drainage ditches for stormwater shall be graded according to the site office layout drawing.
Parking areas as indicated on the site office layout drawing, shall be constructed including
covered shelters where appropriate.
Equipment
Excavator.
Dump trucks.
Crane.
Attachment
ITP No:
Temporary Building Checklist QCF08.

#59

Welding of Earthing Lugs on
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
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                                                                                                                                              131 of




East West Piperack (SR0099A &B)
Top
Index
Scope
Reference documents
Definitions
Responsibilities
Safety
Method
Equipment
Attachment
Scope
The purpose of this Method Statement is to define the sequence and methodology that shall
be implemented for the welding of Earthing Lugs on the columns of the East West Piperack
steel structure.
Reference Documents
Specification Steel Structure Fabrication
Specification Painting
Specification Galvanizing
Specification Structural Steel Erection
Drawing No. (Also Refer E-Mail of 6\11\99) - Attached for Reference
Definitions
PSM Project Site Manager
CM      Construction Manager.
CS      Construction Superintendent
FM      Foreman
Responsibilities
CM shall plan and resource this activity, in accordance with this method statement.
The Construction Foreman shall monitor these activities, directing the workforce as necessary.
The QC inspector shall ensure that the necessary visual inspection is carried out.
Safety
Any process that is adopted having a particular safety risk shall be assessed and addressed
as required.
Method
The location of the Earthing Lugs on the respective columns shall be marked off. Approximate
30mm of the surrounding area shall be cleaned to remove the primer and galvanising.
The Lug shall be initially tack welded to the column and then fully welded to the required fillet
size.
The fillet weld shall be cleaned and free of defects.
Welding shall be done according to the approved WPS using duly qualified welders.
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              132 of



Visual inspection to be done prior to surface finish.
The surface shall be inspected prior to cold galvanizing and painting.
The bare surfaces is made dust free and cold galvanizing applied as a coat with „Jotun Barrier
86”, a two pack zinc-rich epoxy primer.
Allow about 4 Hours for drying.
Make necessary touch-ups using the same grade, colour which were used to paint the
structure-prime coat and the top coat if necessary.
Equipment
Welding Machine
Grinding Machine
Attachment
Drawing N0.
Copy of E-Mail (indicating location of Earthing Lug)
PQR No. QP-009
PQR No. QP-010
WPS No. QW-009
WPS No. QW-010
#60

Filling around all the pipes within the
plant area
Top
Index
Scope
Reference documents
Definitions
Responsibilities
Safety
Method
Equipment
Attachment
Scope
This statement is aimed to propose the procedures to be adopted for the filling around the
GRP pipes within the Plant Area.

Reference Documents
Specification
PSM Project Site Manager
CM     Construction Manager.
CS      Construction Superintendent
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              133 of



FM             Foreman
QC             Quality Control
Responsibilities
CM shall plan and resource this activity in accordance with this method statement.
CS shall control, monitor and direct these activities.
The Construction Foreman shall execute these activities deploying the workforce as
necessary.
The QC inspector shall ensure that the necessary inspection and test are carried out.
Safety
Any process that is adopted having a particular safety risk shall be assessed and addressed
according to Project requirement.
Method
The following activities shall be involved to fill around the pipes laid within the plant area
To fill the sand in 150 mm thickness around the laid pipes
To fill the approved Red fill material in layers in the remaining trench space 150 mm
compacted
Details
The first layer shall be filled 200 mm apprx. compacted to 150 mm.
The field density test shall be conducted for 95 % compaction. A portion of the compacted
material 150 mm radially shall be removed to replace with sand circumferentially .
The sand shall be placed in the first layer portion to replace the filled material
circumferencially.
The structural fill material for the second layer shall be placed in 200 mm thick compacted to
150 mm for 95 % field density and tested according to the specifications.
Again a portion of the compacted material 150 mm radially shall be removed to replace with
sand circumferentially.
The sand shall be placed in the second layer portion to replace the filled material
circumferentially.
Similarly the succeeding layers of fill material shall be placed in 200mm thickness
approximately compacted to 150 mm according to the specifications and replaced by the sand
filling as aforesaid until the apex level of the pipe is covered with sand.
The remaining strata upto the ground level / required level shall be filled in with fill material in
200 mm approximately compacted to 150 mm thick layers according to specifications.
Equipment
Compactor
Attachment
Sketch showing various stages of filling
#61

Precasting man holes
Catch basin and
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              134 of




Valve chambers
Top
Index
Scope
Reference documents
Definitions
Responsibilities
Safety
Method
Equipment
Attachment
Scope
This statement is aimed to propose the procedures to be adopted to precast the manholes,
catch basins and fire water main valve box (wherever so required to be used precast)
chambers and install in specified prepared locations.
Reference Documents
 Drg       Man Holes
 Drg       Man Holes
 Drg       Man Holes
 Drg       Man Holes
 Drg       Catch Basins
 Drg       Catch Basins
 Drg       Catch Basins
 Drg       Typical Details

Specifications
Definitions
PSM Project Site Manager
CM      Construction Manager.
CS      Construction Superintendent
FM      Foreman
QC      Quality Control
Responsibilities
PSM shall control the overall operations
CM shall arrange the resources required accordingly
CS shall control, monitor and direct the FM and workforce for the operations
FM shall execute the operations deploying the workforce
QC shall inspect all the operations according to the specifications
EPC Contractor shall conduct surveillance
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              135 of




Safety
Every day prior to the commencement of any activity, the work personnel shall receive a Tool
Box talk relevant to the operation according to the project safety requirements.
A safety inspector shall inspect the operation daily and direct the Foreman and superintendent
address the snags if any
Method
The following activities shall be involved:
To prepare a precasting yard on site
To fabricate the form works according to design details
To fabricate the box outs to be used in forms
To fabricate the reinforcement
To place the rebars and the non critical cathodic protection
To cast bases with a kicker and shear key as shown in the first stage and cure
To scabble the kicker to roughen the construction joint surface
To cast walls with pipes inlet and outlet boxes formed in the second stage with the lifting hooks
To cure the cast units
To cast the cover slabs in the third stage and cure
Excavation of the relevant area / s
Blinding and membrane
Transportation of the completed open units to the locations
Installation of the units on the correct alignment and levels
Inspections by Civil Contractor QC and EPC Contractor approval
To prepare the cover slab bearing mortar bed as specified
To provide the box out sleeves for steps insertion
Pipe laying by others
To install the seals around the pipes and the box out concrete
To cast the surrounding concrete 150 mm thick as specified
To apply 1 mm thick coal tar epoxy on the external surfaces as specified
To bench the invert levels between the pipe flows where specified
Inspections by Civil Contractor QC and EPC Contractor approval
To plug the pipe spigot ends
To place the covers
Details
A precast yard having a capacity of about 20 units as shown on the attached sketch shall be
used for the precasting operations
The yard shall have convenience for the vehicles to freely move for various activities
Strong platforms of 100 mm thick concrete shall be used as the casting bases / floors
In one go about 10 units shall be made ready for the bottom slab pouring
The overlap shall be provided from the top of the kicker as specified and if so convenient the
rebars shall be fabricated continuously
The formwork for the base slabs with kickers to be cast monolithically shall be prepared
according to the typical sketch attached
Required rebars shall be placed in the correct locations with 75 mm covers / spacers
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              136 of



Shear key forms shall be erected according to the details and well clamped in
Civil Contractor QC inspection shall be conducted followed by EPC Contractor approval
The concrete shall be poured through a chute
The curing shall be carried out by spraying compound and later by saturated hessian and
polythene cover
The wall formwork shall be fabricated on site using marine ply
The internal forms shall be fixed first to the correct dimensions
The box outs shall be fixed to the required locations on the fixed forms
The rebars for the walls as well as the trimming around box outs shall be placed in position
The external forms shall be fixed around well supported, in plumb and correct dimensions
The lifting lugs shall be placed in the required locations in the walls using 16 mm dia rebar
according to the detailed sketch attached
A binding wire length shall be tied to the horizontal rebars in continuity connected to the boss
fixed near wall top for the cathodic non critical arrangement / connection
Civil Contractor QC inspection followed by EPC Contractor approval
Pouring concrete into wall forms with wood float top surface finish and curing by compound
and later by hessian and polythene cover for the specified period
Forming cover slab shutters according to the specified details
Forming the cover box out shutters into the required position
Placing the rebars into the correct positions
Fixing the cover lifting hooks according to details attached
Civil Contractor QC inspection followed by EPC Contractor approval
Pouring concrete and curing as aforesaid
Inserting the steps shall be carried out by fixing the pieces into the preformed holes in the
concrete walls as created by box sleeves with approved grout at a stage when the concrete
has gained sufficient strength
The excavation shall be carried out to the specified level and alignment followed by blinding
and water proofing
The open precast chambers shall be crane lifted and transported by a trailor to the relevant
locations followed by offloading into the correct alignment
The pipes shall be laid by others
After the pipes are laid, specified seals shall be placed in with the surrounding concrete as well
as the box out void forms erected followed by concrete pouring into the box out voids and the
plug(concrete surround)
The benching wherever specified shall be formed according to the channel flows and the
details
The bedding of the joint 20 mm thick shall be carried out on site as specified
After the levels and the alignment are ensured, the cover slab shall be correctly placed in
followed by the formation of the concrete block work pad to suit the cover elevation
The cover shall be set in on the block work pad using cement sand mortar
The mass concrete shall be laid around the cover as specified
The external surfaces shall be applied with 1 mm dry film thickness non solvented coal tar
epoxy in accordance with project specifications
 Civil Contractor QC inspection followed by EPC Contractor approval
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              137 of



The whole levels and the alignment details shall be documented according to requirement
Equipment
Crane
Concrete Transit mixer
Trailer
Vibrator
Attachment
Yard layout
Kicker details
Sketch showing lifting hooks for unit walls and base
Sketch showing lifting hooks for cover slab

  #62
Termination detail to protective membrane around
rcc columns supporting the structural steel
Columns for pipe racks
CASE (1) WITH ALUMINIUM BEAD
CASE (2) WITH REBATE
CASE (3) GRAVEL FILL
CASE (4) PAVING
Top
Index
Scope
Reference documents
Definitions
Responsibilities
Safety
Method
Equipment
Attachment
Scope
This statement is aimed to present the proposed procedures that shall be adopted to clampin
the waterproofing membrane termination using Aluminium Beads around the column sides to
substitute the formation of the conventional rebate partly for the pipe racks foundations and for
the other areas such as hard / soft landscapes.
References
STQ , MAR

Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              138 of



Definitions
PSM                      Project Site Manager
CSM                      Construction Manager
CS                       Construction Superintendent
SE                       Site Engineer
FM                       Foreman
QC                       Quality Control
Responsibilities
PSM shall control the overall operations
CM shall arrange the resources required accordingly
CS shall control, monitor and direct the SE, FM and workforce for the operations
SE shall be responsible for all the site operations and follow the instructions of the CS
FM shall execute the operations deploying the workforce. FM shall explain in full in the
language the work persons understand about all the instruction and the toolbox talks every day
and check that the same are followed up regularly
QC shall inspect all the operations according to the specifications
EPC Contractor shall conduct surveillance
Safety
Prior to the commencement of work, the labour force shall receive a toolbox talk on the Project
Site Safety requirements relevant to the activity involved
Any process adopted which may involve a particular Safety risk shall be assessed to the
requirement for Site conditions and be taken care of.
The personnel shall use the PPE, gloves, masks, eyeglasses etc.
To avoid skin contact, use of barrier cream to protect from the adverse effect of sealant
application shall also be made.
Industrial cleaner shall be used followed by washing with soap and water.
Material safety data shall be referred to for disposal and any further information.
A safety inspector shall visit the site every day and instruct the supervisor in case any snag is
observed who shall immediately implement the instructions accordingly.
Storage
The material including the sealant shall be stored under cover out of direct sunlight and
protected from extreme temperatures. All the manufacturer‟s instructions shall be followed for
the purpose.
Materials
Aluminium Bead lengths to the Sectional dimensions 30 mm x 2 mm
Drilling and fixing screws 3 mm dia
Sealant- Polyurethane-Gun Grade Cold seal 200PF for horizontal usage on Aluminium strip
(Manufacturer BCR) (Emirates Specialities) or equivalent
Method
The following operational sequences shall be involved
Case 1
To cut the Aluminium beads to the exact dimensions according to the column size
requirement.
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              139 of



To provide every column 4 # beads by drilling and fixing using Hilty equipment
To connect the bead to the column side keeping the membrane tacked in by drilling and fixing
screws 3 # each side
To apply sealant a few mm above on the top of the bead covering the bead / column surface
junction and a portion few mm downwards well finished to a smooth profile
Case 2
Where the grooves have already been chased, the waterproofing membrane shall be tacked in
with the sealant applied according to the specifications and the manufacturer‟s instructions. No
Aluminium bead shall be used for this case.
Case 3
Where the area comprises soft landscape such as gravel or soil fill
Case 4
Where the area comprises hard landscape such as paving
Details
Case 1
Application of the waterproofing membrane according to the specifications to the defined levels
keeping the top 200 mm or variable dimension according to the drawing above the finished
ground level
Marking shall be made to the exact line and level to obtain the profile as per drawing
Required lengths to the exact site dimensions shall be cut to suit a close fit between the bead
ends
Every bead shall be provided 3 # minimum screws to be drilled and fixed into the bead and the
concrete penetrating the membrane
The screws shall be fixed using an electrical operated Drill and Screw
After the screws have been fixed into and the beads are in proper alignment / the location,
approved sealant shall be applied to the top of the bead keeping about 5 mm above the bead
with an overlap on the down ward on the bead as follows
Application of sealant
The material shall be applied using a sealant gun fitted with conical nozzles adjustable to suit
the width
The sealant shall be gunned into the junction using an even trigger pressure, cleaning the
nozzle occasionally to avoid contamination. A smaller timber spatula soaked in soapy water
shall be used to compact the sealant into the joint for a smooth polish finish formation.
The mixing and application equipment shall be cured immediately

Civil Contractor QC inspection shall be conducted followed by EPC Contractor approval
Case 2
Where the conventional groove is to be provided, the sealant shall be applied on to the
space left in the groove after the application of the water proofing membrane termination has
been trimmed .The sealant shall be applied around and formed continuous according to the
manufacturer‟s instructions



Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              140 of



Civil Contractor QC inspection shall be conducted followed by the EPC Contractor approval
Case 3
In gravel or soil area the membrane shall be terminated at a level 150mm plus below the
footing top keeping the Aluminium bead strip details typical. All other details shall remain Civil
Contractor QC inspection shall be conducted followed by the EPC Contractor approval
as in case 1 if no rebate be chased
Civil Contractor QC inspection shall be conducted followed by the EPC Contractor approval
Case 4
In the paved area the membrane shall continue upto the termination level but the protection
board cease at 20 mm below the paving level filled with mastic on top keeping all other details
as in case 1 if not chased for rebate
Civil Contractor QC inspection shall be conducted followed by the EPC Contractor approval
Equipment
Electrical operated drill
Sealant applying gun
Attachment
Sketches as in STQ
Case wise description


#63

Termination detail to protective membrane around
rcc columns supporting the structural steel
Columns for pipe racks
CASE (1) WITH ALUMINIUM BEAD
CASE (2) WITH REBATE
CASE (3) GRAVEL FILL
CASE (4) PAVING
Top

Index
Scope
Reference documents
Safety
Method
Equipment
Attachment


Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              141 of




Scope
This statement is aimed to propose the procedures to be adopted to clampin the waterproofing
membrane termination using Aluminium Beads around the column sides to substitute the
formation of the conventional rebate partly for the pipe racks foundations, other structures and
for the other areas such as hard / soft landscapes.
References
MAR (Site fixed sample approved)
Safety
Prior to the commencement of work, the labour force shall receive a STARRT Card / Toolbox
talk on the relevant activity to the Project Site Safety requirements
Necessary measures shall be applied to address any risk involved on any process
The personnel shall use the PPE (gloves, masks, eyeglasses etc.)
Use of barrier cream to protect skin from the adverse effect of sealant shall also be made.
Material safety data shall be referred to for disposal and any further information.
A safety inspector shall visit the site every day and instruct the supervisor in case any snag is
noticed who must immediately implement the instructions
Materials
Aluminium Bead lengths to the Sectional dimensions 30 mm x 2 mm
Screws 3 mm dia
Sealant- Polyurethane-Gun Grade Cold seal 200PF for horizontal usage on Aluminium strip
(Manufacturer BCR) (Emirates Specialities) or equivalent
Method
The following operational sequences shall be involved
Case 1
Concrete surface shall be cleaned of all dirt & dust using a brush
Application of the waterproofing membrane according to the specifications to the defined levels
keeping the top 200 mm or variable dimension according to the drawing above the finished
ground level
Lines shall be marked on all sides to correct level as per drawing
Bead Lengths to exact site dimensions shall be cut to suit a close fit between the ends
Every bead shall be provided with a minimum 3 # screws to be drilled and fastened into the
concrete penetrating the membrane using an electrical operated Drill
After the screws have been fastened and the beads are in proper alignment, approved sealant
shall be applied to top of the bead keeping about 5 mm above the bead with a down ward lap
as follows
Sealant shall be applied using a gun fitted with conical nozzles adjustable to suit the width
into the corner using an even trigger pressure & cleaning the nozzle occasionally to avoid
contamination. A smaller timber spatula soaked in soapy water shall be used to compact the
sealant into the joint / junction for a smooth polish finish formation. The mixing and application
equipment shall be cleaned immediately after use
Civil Contractor QC inspection shall be conducted & the relevant ITP signed off
Case 2

Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              142 of



Where grooves have already been chased, the waterproofing membrane shall be tacked in &
sealant applied to the space left in the groove according to specifications and the
manufacturer‟s instructions. No Aluminium bead shall be used in this case.
Sealant shall be applied around bead continuously
Civil Contractor QC inspection shall be conducted & the relevant ITP signed off
Case 3
In gravel or soil area, membrane shall be terminated at a level „150mm plus‟ below the footing
top level keeping Aluminium bead details typical. All other details shall remain
as in „case 1‟ if no rebate has been chased
Civil Contractor QC inspection shall be conducted & the relevant ITP signed off
Case 4
In the paved area, membrane shall continue upto the termination level but the protection board cease
at 20 mm below the paving level filled with mastic on top keeping all other details as in case 1 if not
chased for rebate
Civil Contractor QC inspection shall be conducted & the relevant ITP signed off
Equipment
Electrical operated drill
Sealant applying gun
Attachment
Sketches
Case wise description
#64
Road crossing for laying 2 pipes 1 for 20” raw ethane & 1 for 6” propane

First street Operating Authority entry
                      Top

Index
Scope
Reference documents
Definitions
Responsibilities
Safety
Method including traffic management scheme
Equipment
Attachment
Scope
The statement is aimed to propose the procedures to be adopted to carry out the excavation at
the road crossing to facilitate to lay the pipe lines 1 # each 20” Raw Ethane and 6” Propane at
location identified on the attached drawing to the following references
Reference documents
Specification. Excavation & Backfilling for Underground structures.
Drawing No.
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              143 of



Easement Systems 1 ST Street
Piping Interconnection Drawings, First Street
Definitions
PSM           Project Site Manager
CSM           Construction Manager
CS            Construction Superintendent
SE            Site Engineer
FM            Foreman
QC            Quality Control
Responsibilities
PSM shall control the overall operations
CM shall arrange the resources required accordingly and be overall responsible for the
excavation operation
CS shall control, monitor and direct the SE, FM and workforce for the operations
SE shall be responsible for all the site operations and follow the instructions of the CS
Any mishap on the excavation operation shall immediately be notified to the CS and the CM for
the immediate action if so required for any possible remedy or record or the authority review
whatsoever,the case may be
FM shall execute the operations deploying the workforce. FM shall explain in full in the
language the work persons understand about all the instruction and the ToolBox talks every
day and check that the same are followed up regularly
QC shall inspect all the operations according to the specifications
EPC Contractor shall conduct surveillance
Safety
Prior to the commencement of any activity the labour force shall receive a Toolbox talk
relevant to the operation concerned on the project site safety requirements. Any process is
adopted having a particular safety risk shall be assessed and addressed as required to raise to
a minimum standard / an acceptable mark.
In the present case the excavation has to be carried out on the Operating Authority area,
therefore all the regulated precautions shall be resorted to effect a full safety standard.
ToolBox Talks-
While conducting ToolBox Talks, a representative from the authority shall be involved to
witness and sign the instruction imparted with the workers prior to the commencement of the
operations to make a record. Only English literate Foreman shall be employed to work on the
excavation execution.
Excavation Work Permit- A copy of the work permit shall be posted on a mini board installed
on site to be noticeable to all the relevant persons involved on the crossing
Traffic Management-Sign boards keep up-All the personnel shall be briefed about the safe
keep up of the boards
Barricades,cones, markers and the night-lights, flood lights etc. shall be arranged as required
for a complete safety. No oil spillage shall be allowed.
The sides of the excavation shall be sloped with the barriers placed to indicate the excavation
work in progress
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              144 of



Flagman-On both the direction, in addition to the traffic sign boards, a flagman shall be
engaged to operate full time to direct the traffic about the excavation work in progress by
waving the flag for all the vehicles passing by
Hand Excavation- Excavation required to be by hand shall only be carried out manually. In
case certain services not shown on the record drawings such as fibre optics cable is
discovered, the excavation shall be ceased to be continued until the decision to hydrojetting
is taken up and the authority are involved.
Jack Hammer- The worker engaged on operating this equipment shall use protective glass
and work in phases with pause intervals. The compressor air pressure shall be monitored from
time to time so that the hammer works smoothly. The compressor shall be place within the
barricade limits
Access to trench- The workers shall clearly be instructed to use only the ladders to enter in or
come out. No jumping shall be allowed
Machine Excavation
The operators shall be explicitly explained and instructed about the requirement of the reverse
signal and sound when operating reverse. The truck driver shall also be instructed similarly.
Banksman shall be engaged while the equipment operate.
No violation of the traffic rules shall be allowed
Deep Trenches
If required, the shoring shall be provided to prevent the caving in. In case of the trench depth
being more than 1200 mm. Adequate means of exit such as Aluminium ladder or steps shall
be provided and located no more than 8 m of lateral travel.
Plants preservation
The live plants and the trees arboricultured shall be deplanted integrally with the roots and
preserved to the specialist requirement so that these remain live till the replantation is carried
out all to the satisfaction of the specialist
Safety Supervision
A competent inspector shall inspect the trench daily to assess the safety measures adopted.
Method
The required permit to work shall be obtained from the Plant Refinery Division.
The record drawings regarding the existing services shall be obtained.
A traffic management scheme has been presented herein and shall be produced on site as
detailed on the attached sketch for this road crossing which includes, reduced speed sign,
temporary diverted roads sign, men at work sign, warning signs, informatory signs, safety
barriers, night lighting and road cleaning activities.
The traffic management scheme shall be reviewed and approved by EPC Contractor prior to
commencing the work.
The aforesaid traffic management scheme shall be implemented as described below:
TRAFFIC MANAGEMENT SCHEME ROAD CROSSING – First Street
Drawing reference –
This proposed crossing is located on the road 1 st Street between the following co-ordinates as
shown on the referred drawing.
This is a 2-way road with a central verge and carrying 1 lane on either way

Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              145 of



Both ends of the crossing are existing earthen ramp. On the central verge 4 minor irrigation
pipes are in service. On the West Side, one irrigation pipe is in service. On the East Side one
irrigation pipe is disconnected. On the central verge one electric pole is in service. In addition
to the aforesaid tiny plants are arboricultured.
The proposed crossing is just situated at the access road to Operating Authority gate.
 The road shall be divided in 2 parts as shown on the sketch as lane L1 and L 2 on either side
of the carriageway
In the first instance the work shall be carried out on L1 diverting the traffic to the road portion
on L2 as shown on the sketch.
In the second instance the work shall be carried out on L2 diverting the traffic to the road
portion on L1 as shown on the sketch.
The road x-ing lies on the branch road hence one directory sign shall be fixed on both east and
west side of the 1st street road at 200m from the location to indicate the work ahead .on the left
and right directions respectively.
The first board depicting „reduce speed‟ for traffic diversion informatory shall be located at 100
m from the point of the proposed crossing and the second depicting „men at work‟ sign be
located at 100 m on either way in the opposite directions.
A Flagman shall be engaged full time on both the directions to guide the traffic about the
ongoing excavation operations in addition to the conventional signboards
The following activities are involved. Reference to the marked note „B‟ on the Easement
Systems Drawing
To produce the Traffic Management Scheme
To divert the minor irrigation, electric pole, plants etc. temporarily as required.
To excavate by hand and expose all the underground facilities
(5.5KV / 0.24KV cables are available)
Trial pit to be excavated in size (5mx2mx1.5m) deep by hand tools
To seam the area with the detectors to ascertain the existing cables.
To expose the cable fully and to be inspected by the authorities / Operating Authority
After the exposure & diversion, the cables to be covered with split PVC pipes by others
To continue the excavation mechanically according to the authority directions / and as
agreed
To excavate the remaining portion by the excavator machine
To have authority inspection
The pipes to be laid by others
To fill the bedding material according to the specification requirement
To reinstate the diverted services
To reinstate the central verge to the existing state
Details
The Traffic Management Scheme shall be executed as explained in the foregoing and to the
traffic manual directions.
The first section of road crossing on both sides as per the attached sketch shall be marked by
the surveyor on the actual location.
The asphalt shall be cut using jack hammers.

Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              146 of



The road section shall be excavated to expose the existing cables manually for which the trial
pit may be made prior the full manual excavation is proceeded with.
The existing electrical pole shall be diverted accordingly.
The minor irrigation lines shall be diverted according to the Officials instructions.
The plants shall be taken off the site for preservation
After the exposure of the cables, the Operating Authority authorities shall inspect and the
cables be diverted accordingly following which the remaining machine excavation be carried
out to the specified levels
The excavated material shall be removed from the site to stockpile area.
Appropriate bedding material shall be placed within the excavated trench to the correct service
level. Where required, this bedding shall be compacted and tested.
The excavated trench shall be inspected by the authorities as required.
The potable and the Desalinated water pipes shall be laid by others.
Backfill around the service pipes shall be carried using the appropriate material.
The service pipes surrounding material shall be compacted as per the project specification
requirements. Test results shall be provided for the specification conformance verification.
The existing services shall be reinstated accordingly.
The plants or trees if removed and so required, shall be reinstated accordingly.
General fill up to the underside of road formation shall be placed in 150mm compacted layers
using mechanical methods to the specification requirements.
A concrete slab shall be cast up to the bottom of the finished asphalt level.
The finishing shall be carried out using approved asphalt mix.
The traffic management system shall be removed after the road crossing has been cleaned of
any debris or obstructions.
Either side of the road shall be provided with cable markers to indicate the services
Major Equipment
Excavator.Dump trucks.Compactors.
Jack Hammer, Compressor,
Attachment
Sketch showing the traffic management scheme
Drawings including the traffic diversion

#65




Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              147 of




Road crossing for laying 2 pipes
1 for 20” raw ethane
&
1 for 6” propane
First street Operating Authority entry
        Top

Index
Scope
Reference documents
Safety
Method including traffic management scheme
Equipment
Attachment
Scope
The statement is aimed to propose the procedures to be adopted to carry out the excavation at
the road crossing to facilitate to lay the pipe lines 1 # each 20” Raw Ethane and 6” Propane at
location identified on the attached drawing to the following references
Safety
Prior to the commencement of any activity the labour force shall receive a / STARRT card /
Toolbox talk. Any process involving a particular safety risk shall be assessed and adopted
measures addressed to raise to a minimum standard
In this case the excavation has to be carried out on the Operating Authority area, therefore all
the regulated precautions shall be strictly adhered to effect a full safety standard.
Excavation Work Permit- A copy of the work permit shall be posted on a mini board installed
on site to be noticeable to all the persons involved on the crossing
Barricades, cones, markers, the night-lights, and floodlights etc. shall be installed as required
for a complete safety. No oil spillage shall be allowed.
Flagman-On both directions, in addition to the traffic sign boards, a flagman shall be engaged
full time to direct the traffic about the excavation work in progress by flag signal
Hand Excavation- Excavation to expose the services be carried out manually. In case certain
services not shown on the record drawings such as fibre optics but it is discovered, further
excavation shall be ceased and hydrojetting applied.
Access to trench- The workers shall clearly be instructed to use only the ladders to enter in or
come out. No jumping shall be allowed
Machine Excavation


Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              148 of



The operators / drivers shall be explicitly instructed to abide by the requirement of the reverse
signal and sound when operating reverse. Banksman shall be engaged while the equipment
operates. No violation of the traffic rules shall be allowed
Method
The required permit to work shall be obtained from the Plant Refinery Division.
The record drawings regarding the existing services shall be obtained.
A traffic management scheme shall be produced as detailed on the attached sketch
Drawing reference Piping Interconnections        First Street‟:
Existing Services
One lighting pole is located on the central verge adjacent to the proposed excavation
The minor irrigation / hoses exist to irrigate the central verge plantation
Some minor trees and plants are also growing on the central verge.
The road shall be divided in 2 parts as shown on the sketch as L1 and L 2
In the first instance the work shall be carried out on part L1 diverting the traffic to the road
portion on the part L2
In the second instance the work shall be carried out on part L2 diverting the traffic to the road
portion on the completed road portion on the part L1
Instance 1
The asphalt shall be removed
Hand excavation shall be carried out to expose the cables & other services by seaming the
area with detectors
After the exposure, all the cables shall be covered with split PVC pipe to continue the
excavation mechanically
Remaining portion of the trench shall be excavated by machine
Preparation of the trench to lay RCC pipe sleeves shall be carried out
Bedding material shall be laid to receive the pipe sleeves
Pipe sleeves with dia 8 “ more than the specified respective pipes dia shall be laid to the
design alignment and levels
Filling over the pipe sleeves shall be carried out to specifications
The diverted services shall be reinstated
Backfilling up to the road formation shall be carried out to specifications
The above operations shall be repeated for Instance 2
The central verge shall be made good & the diverted services reinstated
A 70 mm thick layer of concrete shall be laid in place of the asphalt concrete. This shall be
subsequently broken out and replaced by asphalt when the asphalt plant is next in operation
The traffic management scheme shall be removed after the road crossing is cleared of all
debris and obstructions.
Either side of the road shall be provided with cable markers to indicate the services
Major Equipment
Excavator, Dumper trucks, Compactors. Jack Hammer, Compressor,
Attachment
Sketch showing the traffic management scheme #66

Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              149 of




Directional boring
For laying sleeves for
2 pipes
1 # 20” raw ethane
&
1 # 6” propane
Operating Authority Plant refinery entry
                                 Top

Index
Scope
Reference documents
Safety
Method
Equipment
Attachment
Scope
The statement is aimed to propose the procedures to be adopted to carry out the directional
boring under the road to facilitate to lay the sleeves for pipe lines 1 # each 20” Raw Ethane
and 6” Propane at location identified on the attached drawing to the following reference
Drawing reference –Piping Interconnections First Street:
Safety
Prior to the commencement of any activity the labour force shall receive a / STARRT card /
Toolbox talk. Any process involving a particular safety risk shall be assessed and adopted
measures addressed to raise to a minimum standard
In this case the excavation has to be carried out on the Operating Authority area, therefore all
the regulated precautions shall be strictly adhered to effect a full safety standard.
Excavation Work Permit-
A copy of the work permit shall be posted on a mini board installed on site at the location
shown on the sketch to be noticeable to all the persons involved
A copy shall also be transmitted to EPC Contractor
Barricades, cones, markers, the night-lights, and floodlights etc. shall be installed as required
at the pits for a complete safety.
Method
The necessary permit to work shall be obtained from the Plant Refinery Division.
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              150 of



The record drawings regarding the existing services shall be obtained
2 # trial pits shall be made manually on both ends of the proposed boring to ascertain the
availability of the existing services and protect these from any damage and shall also be used
for the bentonite trial at the receiving end
On site, sufficient excavated space is available to lower the sleeve in to pull into the bore
On Eastern end, some electric cable is existing
2 # 24” pipe lines are also existing adjacent to the proposed route
Minor trees on both ends may be effected in the roots
The excavated trench does not show any sign of water therefore, no de watering shall be
carried out
Excavation shall be carried out according to the requirement
On East End missing the berm, boring machine shall be positioned in the trench at about
3 m from the berm
The boring shall be carried out in stages.
First stage-
The sleeve is in the trench on the West end and the reamer fully underground.
Second stage-
The sleeve is partly pulled in and the reamer partly withdrawn
Third stage-
The sleeve further pulled and the reamer withdrawn accordingly
Fourth stage-
Full portion of the sleeve is underground in the bore and the reamer out
The excavated trenches on both ends shall be backfilled by Civil Contractor according to the
specification requirement and the required tests carried out
The reinstatement of the effected services shall be carried out after the directional boring is
completed
Directional Boring – A non- excavation Method which does not allow collapsing of the ground
surface
M / S Ditch Witch shall carry out the Directional Boring employing Jet Trac Directional Boring
equipment according to their method statement attached.
Refer to the attached sketches based on the Ditch Witch guidelines
Bentonite is pure clay to be used as a fluid / slurry formed by mixing water. It shall be used
to cool the drill bit and to lubricate the drill area
The material displaced by the head / sleeves shall be discharged at the receiving end in the
receiving pit and removed from the site
All fully trained operators shall be used on the job
Major Equipment
Jet Track Unit (complete package), Crane, Compactor
Attachment
Plan of the area indicating trial pits etc
Ditch Witch Method Statement
Cross-Section Sketches showing the indicative procedures
#67
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              151 of




Top


Index
Scope
Reference documents
Safety
Method
Equipment
Attachment
Scope
The statement is aimed to propose the procedures to be adopted to carry out the thrust boring
under the road to facilitate to lay the pipe lines 1 # each 20” Raw Ethane and 6” Propane at
location identified on the attached drawing to the following reference
Drawing reference –Piping Interconnections          First Street
Safety
Prior to the commencement of any activity the labour force shall receive a / STARRT card /
Toolbox talk. Any process involving a particular safety risk shall be assessed and adopted
measures addressed to raise to a minimum standard
In this case the excavation has to be carried out on the Operating Authority area, therefore all
the regulated precautions shall be strictly adhered to effect a full safety standard.
Excavation Work Permit- A copy of the work permit shall be posted on a mini board installed
on site to be noticeable to all the persons involved
Barricades, cones, markers, the night-lights, and floodlights etc. shall be installed as required
at the pits for a complete safety.
Traffic Signs- Necessary traffic signs at the pits shall be provided
Hand Excavation- Excavation to ascertain the routes of the existing services encountered
during Thrust Boring in case not shown on the record drawings shall be carried out manually.
Method
The necessary permit to work shall be obtained from the Plant Refinery Division.
The record drawings regarding the existing services shall be obtained.
Non Excavation Method
Necessary drive and receiving pits shall be excavated by Civil Contractor according the
approved procedures
M / S Ditch Witch shall carry out the Thrust Boring employing Jet Trac Directional Boring
according to the brief procedures given below
The Jet Track unit shall be anchored to the ground surface using hydraulically operated anchor
stakes
The directional boring / Angled bit shall be drilled into the ground using fluid assistance to
operate.

Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              152 of



Bentonite and water shall be used to form a fluid to be sprayed at low pressure ejected out of
the drill head to lubricate the drill procedure as well as to cool electronic tracking components
in the drill head
An electronic receiver shall be used to track the head from the ground surface and when the
directional control is required, the head shall be pushed by the drill unit without rotation until
the drill head angle is reached
Head shall be steered to the ground surface when it reaches the destination end
Then Drill head shall be removed from the drill pipe and a backreamer with a pipe puller
attached alongwith the pipe / s to be installed underground
During backreaming, the drill fluid shall assist the backreamer lubricate and form slurried area
for the installable pipe
Backreaming and pipe pulling simultaneously shall allow the pipe to be installed underground
without excavation and continue until the backreamer and pipe reach the launch end of the
Directional bore accomplishing boring complete
Necessary tests shall be carried out by EPC Contractor
Major Equipment
Jet Track Unit complete package
Attachment
Ditch Witch Method Statement
Sketches showing the indicative procedures
#68
2 #s road crossings For laying
1 for 14” desalinated water
1 for 8”potable water
&
1 for 20” raw ethane
1 for 8” natural gas
1 for 6” propane
Avenue „c‟
At fire station
Top

Index
Scope
Safety
Method including traffic management scheme
Equipment
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              153 of



Attachment
Scope
The statement is aimed to propose the procedures to be adopted to carry out the excavation at
the road crossings to construct culverts to facilitate to lay the pipe lines
1 # each 14” Desalinated water, 8” Potable water and
1 # each 20” Raw Ethane, 8” Natural Gas and 6” Propane
at locations identified on the attached drawing pertaining to avenue C
at existing Fire Station
Safety
Prior to the commencement of any activity the labour force shall receive a / STARRT card /
Toolbox talk. Any process involving a particular safety risk shall be assessed and adopted
measures addressed, to raise to a minimum standard
In this case the excavation has to be carried out on the Operating Authority area, therefore all
the regulated precautions shall be strictly adhered to have „ full safety standard‟ effect.

Safety Supervision
A competent inspector shall visit the area daily to assess the safety measures adopted. Any
snag observed during his visit shall be notified to the supervisor present who immediately act
to bring the adopted safety measures to an acceptable standard
In case of incident where utilities not identified are discovered or damaged, all work shall stop
in the area and the Operator Shift Controller and HSE department immediately notified
Phone number :
Shift Controller
Emergency Number
HSE Direct number
Employees working in easement area shall have a daily pre-task briefing that includes;
Reporting of incidents
Methods of work and tools to be used
Potential hazards found in the Easement areas
The approved work method statement
EPC Contractor and Civil Contractor HSE department shall participate in presenting the
STARRT card briefing and monitor the activities to ensure that the work methods are being
followed and all personnel have an understanding of the hazards associated with working
adjacent to live process areas
Excavation Work Permit- A copy of the work permit shall be posted on a mini board installed
on site to be noticeable to all persons involved with the crossing
Barricades, cones, markers, night-lights, and floodlights etc. shall be installed as required for a
complete safety. No oil spillage shall be allowed.
Flagman-On all directions, in addition to the traffic sign boards, flagmen shall be engaged full
time to direct the traffic about the „excavation work in progress‟ by „flag signal‟
Hand Excavation- Excavation to expose the services shall be carried out manually.



Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              154 of



In case certain services not shown on the record drawings such as fibre optics but it is
discovered, further excavation shall be ceased until a decision is taken for the method to be
adopted for further excavation
Access to trench- The workers shall clearly be instructed to use only the ladders to enter in or
come out of the trench. No jumping shall be allowed
Machine Excavation
The operators / drivers shall be explicitly instructed to abide by the requirement of the reverse
signal and sound when operating reverse. Banksman shall be engaged during equipment
operation. No violation of the traffic rules shall be allowed
Pre cast members
Since pre cast culvert units, covers and sleepers are heavy in load, proper care has to be
exercised during raising & downing (handling) to the exact locations strictly adhering to the
relevant safety measures
Method
The required permit to work shall be obtained from the Plant Refinery Division.
The record drawings regarding the existing services shall be obtained.
A traffic management scheme shall be produced as detailed on the attached sketch
Drawing reference – Piping Interconnections         Road Avenue „C‟: N
Existing Services
One serving electric pole is located away from the crossing towards North
The minor irrigation / hoses exist to irrigate the central verge plantation
Street light electric cables exist & Some minor plants also growing on the central verge.
The road shall be excavated in one instance by diverting the traffic on both sides as shown
Procedures
Backfilling shall be carried out to the existing excavated cross trenches on both end of the
proposed crossings up to the natural ground level to provide effective traffic „divertion routes‟
from the road carriageways according to the traffic management scheme attached
Traffic management scheme shall be implemented effectively
Existing services from the central verge shall be diverted or protected as required and directed
by the competent concerned authority
The asphalt and the central verge pertaining to the crossings portion shall be removed
Hand excavation shall be carried out to expose the cables & the other services by seaming the
area with detectors
After the exposure, all the cables shall be covered with split PVC pipe & well supported
temporarily to continue the excavation mechanically
Remaining portion of the trench shall be excavated by machine to the defined levels
Preparation of the trench to construct RCC culverts shall be carried out
The construction pertaining to the pipe carrying culverts including the laying of pipe sleepers
anchored with standard dowels, covers, fixing steps etc.shall be carried out according to the
drawings and the approved procedures using pre cast RCC units / members
In addition, one access boxout on both ends shall be provided to design details
The diverted services shall be reinstated
Inspections shall be conducted to the requirement
Backfilling up to the road formation shall be carried out according to specifications
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              155 of



The central verge shall be made good & the diverted services reinstated
The broken asphalt portion shall be made good using new asphalt
The traffic management scheme shall be removed after the road crossing is cleared of all
debris and obstructions.
75 mm dia holes in the pre cast units meant for lifting shall be filled with concrete
Access boxout shall be closed with concrete after the pipes are laid
Either side of the road shall be provided with cable markers to indicate the services
8 mm galvanised removable chequer plate covers with 2 lifting handles shall be provided to
design details
Major Equipment
Excavator, Dumper trucks, Compactors. Jack Hammer, Compressor, Asphalt finisher, Road
Rollers
Attachment
Sketch showing the traffic management scheme
#69
2 #s road crossings
For laying
1 for 14” desalinated water
1 for 8”potable water
&
1 for 20” raw ethane
1 for 8” natural gas
1 for 6” propane
Avenue „c‟ At fire station
Top

Index
Scope
Safety
Method including traffic management scheme
Equipment
Attachment
Scope
The statement is aimed to propose the procedures to be adopted to carry out the excavation at
the road crossings to construct culverts to facilitate to lay the pipe lines
1 # each 14” Desalinated water, 8” Potable water and
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              156 of



1 # each 20” Raw Ethane, 8” Natural Gas and 6” Propane at locations identified on the
attached drawing pertaining to avenue C / First Street Road Crossing at existing Fire Station
Safety
Prior to the commencement of any activity the labour force shall receive a / STARRT card /
Toolbox talk. Any process involving a particular safety risk shall be assessed and adopted
measures addressed, to raise to a minimum standard
In this case the excavation has to be carried out on the Operating Authority area, therefore all
the regulated precautions shall be strictly adhered to have „ full safety standard‟ effect.
Safety Supervision
A competent inspector shall visit the area daily to assess the safety measures adopted. Any
snag observed during his visit shall be notified to the supervisor present who immediately act
to bring the adopted safety measures to an acceptable standard
In case of incident where utilities not identified are discovered or damaged, all work shall stop
in the area and the Operator Shift Controller and HSE department immediately notified
Phone number :
Shift Controller
Emergency Number
HSE Direct number
Employees working in easement area shall have a daily pre-task briefing that includes;
Reporting of incidents
Methods of work and tools to be used
Potential hazards found in the Easement areas
The approved work method statement

EPC Contractor and Civil Contractor HSE department shall participate in presenting the
STARRT card briefing and monitor the activities to ensure that the work methods are being
followed and all personnel have an understanding of the hazards associated with working
adjacent to live process areas
Excavation Work Permit- A copy of the work permit shall be posted on a mini board installed
on site to be noticeable to all persons involved with the crossing
Barricades, cones, markers, night-lights, and floodlights etc. shall be installed as required for a
complete safety. No oil spillage shall be allowed.
Flagman-On all directions, in addition to the traffic sign boards, flagmen shall be engaged full
time to direct the traffic about the „excavation work in progress‟ by „flag signal‟
Hand Excavation- Excavation to expose the services shall be carried out manually.
In case certain services not shown on the record drawings such as fibre optics but it is
discovered, further excavation shall be ceased until a decision is taken for the method to be
adopted for further excavation
Access to trench- the workers shall clearly be instructed to use only the ladders to enter in or
come out of the trench. No jumping shall be allowed
Machine Excavation
The operators / drivers shall be explicitly instructed to abide by the requirement of the reverse
signal and sound when operating reverse. Banksman shall be engaged during equipment
operation. No violation of the traffic rules shall be allowed
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              157 of



Pre cast members
Since pre cast culvert units, covers and sleepers are heavy in load, proper care has to be
exercised during raising & downing (handling) to the exact locations strictly adhering to the
relevant safety measures
Method
The required permit to work shall be obtained from the Plant Refinery Division.
The record drawings regarding the existing services shall be obtained.
A traffic management scheme shall be produced as detailed on the attached sketch
Drawing reference Piping Interconnections        Road Avenue „C‟:
Existing Services
One serving electric pole is located away from the crossing towards North
The minor irrigation / hoses exist to irrigate the central verge plantation
Street light electric cables exist & Some minor plants also growing on the central verge.
The road shall be excavated in two instances by diverting the traffic on either lane completing
one after the other as shown on the traffic management scheme
Procedures
Traffic management scheme shall be implemented effectively
Existing services from the central verge shall be diverted or protected as required and directed
by the competent concerned authority
Instance 1
The asphalt and the central verge pertaining to the crossing portion Stage-1 shall be removed
Hand excavation shall be carried out to expose the cables & the other services employing
seaming the area with detectors to detect the existence of cables
After the exposure, all the cables shall be covered with split PVC pipe & well supported
temporarily to continue the excavation mechanically
Remaining portion of the trench shall be excavated by machine to the defined levels
Preparation of the trench to construct RCC culverts shall be carried out
The construction pertaining to the pipe carrying culverts including the laying of pipe sleepers
anchored with standard dowels, covers, fixing steps etc.shall be carried out according to the
drawings and the approved procedures using pre cast RCC units / members
In addition, one access boxout at the end shall be provided to design details
The diverted services shall be reinstated
Inspections shall be conducted to the requirement
Backfilling up to the road formation shall be carried out according to specifications
The broken asphalt portion shall be made good using new asphalt
Instance 2
The aforesaid activities shall be repeated for this instance for the crossing portion Stage-2
The central verge shall be made good & the diverted services reinstated
The traffic management scheme shall be removed after the road crossing is cleared of all
debris and obstructions.
75-mm dia holes in the pre cast units meant for lifting shall be filled with concrete
Access boxout shall be closed with concrete after the pipes are laid
Either side of the road shall be provided with cable markers to indicate the services

Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              158 of



8 mm galvanised removable chequer plate covers with 2 lifting handles shall be provided to
design details. Other chequer plates shall be provided to the design details
Major Equipment
Excavator, Dumper trucks, Compactors. Jack Hammer, Compressor, Asphalt finisher, Road
Rollers
Attachment
Sketch showing the traffic management scheme


#70
Administration building
GRC Panel fixing
Top

Index
Scope
Reference documents
Definitions
Responsibilities
Safety
Method Equipment
Attachment
Scope
The statement is aimed to propose the procedures to be adopted to carry out the fixing of
preformed GRC panels to columns, parapet and horizontal bands ( locations where there are
no projected beams and also where the projected beams exist).
Reference documents
Drawings- ELEVATIONS
FIBREX Shop Drawings and
Statement
Definitions
PSM         Project Site Manager
CSM         Construction Manager
CS          Construction Superintendent
FM          Foreman
QC          Quality Control
Responsibilities
PSM shall control the overall operations
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              159 of



CM shall arrange the resources required accordingly
CS shall control, monitor and direct the FM and workforce for the operations
FM shall execute the operations deploying the workforce
QC shall inspect all the operations according to the specifications
EPC Contractor shall conduct surveillance
Safety
Prior to the commencement of any activity the work force shall receive a Toolbox talk relevant
to the operation concerned on the project site safety requirements. Any process is adopted
having a particular safety risk shall be assessed and addressed as required to raise to a
minimum standard / an acceptable mark.
Adequate scaffolding shall be provided for the safe access to the work location
Safety harness shall be provided for the personnel working at heights
Method
The work of the GRC manufacturing and fixing shall be carried out by the
Fibrex Co. W.L.L PO Box #
All the metal hanger sub frames exposed surfaces shall be painted to specifications
Fixing Column Panels
The floor finish level shall be marked and the bottom defined.
The bottom fixing level shall be marked using a template corresponding to the GRC bottom
panel situation.
2 #s Stainless Steel bracket 75x75x6 mm shall be fixed with 10 mm S / S Parabolt pins
drilled on the wall
The bottom panels C1 shall be located to the final true position with slotted holes in GRC
panels prefilled with Polyurethane mastic prior to placing
Stainless Steel double side pin bracket 75x75x6mm shall be fixed on the top of the bottom
panels to have a pin penetration at least 25 mm inside the slot at bottom panel to act as a
lateral restraint with 25mm protrusion beyond top( panel top) level.
FIBREX Drawing Ref
The inverted S / S upper restraint bracket shall be fixed with over sized hole at the C1S panel
top cast in sockets and the panel fixed to the bracket with M10 S / S bolt.
The upper panel C1S shall be located and aligned to the final level and position
The panel shall be fixed to the bracket with M10 S / S bolt
The foregoing sequence shall be repeated for the other column panels
The panel joints shall be filled with Polyurethane sealant
Civil Contractor QC inspection shall be conducted followed by the EPC Contractor approval
Fixing Parapet Panels
The bottom level of the panel and the location of the steel box brackets shall be marked
according to the details on the FIBREX shop drawings
The steel box brackets shall be fixed to walls according to the details on the drawings
The horizontal 70x60x6 mm U channels shall be fixed to the box bracket at 3 levels as marked
on the drawing
16 mm holes shall be drilled on U channels corresponding to the panel fixing points using
template
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              160 of



75x75x6xmm steel brackets shall be fixed with over sized holes to the wall locations
corresponding to the cast in sockets in the GRC panels. (Ref drg)
GRC panels shall be located and aligned to the final level and position
The panel cast in socket shall be fixed to the bottom bracket with 10 mm S / S bolt with
washer
2 # S / S brackets shall be fixed on the concrete parapet corresponding to the cast in socket
on the top level of the panel and the panel be fixed with the bracket with M 10 threaded bar,
nuts and washers
The top GRP cover shall be fixed and screwed in
to the GRC panel on one side and parapet on the other as shown on the shop drawing
All the slots / exposed fixings locations shall be closed with GRC closing pieces
The foregoing sequence shall be repeated for the other panels also
The panel joints shall be filled with Polyurethane sealant
Civil Contractor QC inspection shall be conducted followed by the EPC Contractor approval
Fixing Horizontal Bands
Fixing at locations where there is no projected beams
The level and the fixing locations shall be marked on the wall according to the details on the
shop drawings
2 # 75x75x6mm S / S brackets shall be fixed with pin on the marked locations
2 # 75x75x6mm S / S brackets shall be fixed with hole at higher level as shown on the shop
drawing
The panel shall be located and aligned to final level and position.
Slotted holes in GRC panels shall be prefilled with Polyurethane mastic prior to placing
The panel shall be fixed to the top brackets with S / S M 10 bolts
The top fixing slot shall be closed with GRC closing pieces
The foregoing sequence shall be repeated for the other panels also
The panel joints shall be filled with Polyurethane sealant
Civil Contractor QC inspection shall be conducted followed by the EPC Contractor approval
Fixing at locations where there is projected beams
The level and fixing locations shall be marked on the wall as shown on the shop drawing
12 mm dia holes shall be drilled on the wall fixing locations
M10 threaded bars shall be fixed to the panels „cast in sockets 4 #‟ in the panel
4# holes on the wall shall be filled with chemical (Upat chemical anchors)
The panel shall be located and aligned to final level and position
The panel shall be held until the chemical dries
The foregoing sequence shall be repeated for the other panels also
The panel joints shall be filled with Polyurethane sealant
Civil Contractor QC inspection shall be conducted followed by the EPC Contractor approval

Major Equipment
Attachment
Fibrex Statement

Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              161 of



#71


Painting
Administration building
Top

Index
Scope
Reference documents
Definitions
Responsibilities
Safety
Method
Equipment
Attachment
Scope
This statement is aimed to present the proposed procedures that shall be adopted to apply the
Painting System on the above building on various surfaces according to the specifications and
the material system approved.
References
Specifications DG
MAR #
Definitions
PSM           Project Site Manager
CSM           Construction Manager
CS            Construction Superintendent
FM            Foreman
QC            Quality Control
Responsibilities
PSM shall control the overall operations
CM shall arrange the resources required accordingly
CS shall control, monitor and direct the FM and workforce for the operations
FM shall execute the operations deploying the workforce
QC shall inspect all the operations according to the specifications

EPC Contractor shall conduct surveillance
Safety
Prior to the commencement of work, the labour force shall receive a Toolbox talk relevant to
the operation concerned to the Project Site Safety requirements.
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              162 of



Any process that is adopted which may have a particular Safety risk shall be assessed to the
requirement for Site conditions and be taken care of.
The personnel shall use the PPE, gloves, masks, eyeglasses etc and to avoid skin contact.
use of barrier cream shall also be made.
Material safety data shall be referred to for disposal and any further information.
Adequate arrangement shall be made to provide access to the top of the wall.
Adequate scaffolding with proper netshade shall be provided wherever required
The personnel shall use the waist safety belt / harness while working on height.
Immediate medical care shall be provided in case the eyes of any personnel are effected due
to the paint splashes or any other reason
Proper ventilation shall be provided to let the workers respirate properly
A safety inspector shall visit the site every day and instruct the supervisor in case any snag is
observed who immediately implement the instructions accordingly.
Storage
The material shall be stored under cover out of direct sunlight and protected from extreme
temperatures. Shelf life 12 months between 5 deg and 35 Celsius
Materials
Berger Paint systems
MAR #

Table 1
S # Sub Strata                                           Surface preparation                                            Operating
                                                                                                                        temperature
1           Galvanised        steel-                     Mechanical cleaning                             to      remove Upto 100 deg C
            Exterior,Polyurethane                        loose deposits
2           Mild      steel-Exterior,                    Blasting to Sa 2.5                                                         Upto 100 deg C
            Polyurethane
3           Concrete        Surface-                     Cleaning with sand stone to Upto 100 deg C
            Exterior,                                    smoothen the surface free from all
            Polyurethane                                 dirt etc
            textured
4           Galvanised        Steel-                     Mechanical cleaning to remove Upto 60 deg C
            Interior, Alkyd                              loose deposits
5           Galvanised        Steel-                     Mechanical cleaning to St 2 to Upto 60 deg C
            Interior,        Primed                      remove loose rust, scales
            ferrous metal Alkyd
6           Plaster and Gypsum-                          Cleaning with fine emery paper to Upto 50 deg C
            Gypsum wall board                            remove dirt etc.
            and plaster, Acrylic




Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              163 of




System # 1, Exterior Surfaces –Galvanised Steel, Polyurethane
Table 2
Coats   Generic       # of Solids   DFT      Colour Applicat                                                                                              Berger
        Type          coat volume Microns             ion                                                                                                 Product
                      s    %
Primer Surface        1    82       100      Alumini Brush /                                                                                              Epimast
        tolerant                             um       Spray                                                                                               ic 5100
        high build                                                                                                                                        Al
        epoxy
Finish  Gloss         1    50       50       White / Brush /                                                                                              Robbiat
        Polyurethan                          Colours Spray                                                                                                hane
        e
                      2             150

System # 2, Exterior Surfaces –Ferrous Metal, Polyurethane
Table 3
Coats                Generic                # of                  Solids                DFT                   Colour                Applicat Berger
                     Type                   coat                  volume                Microns                                     ion      Product
                                            s                     %
Primer  High                          build 1                     57                    75                    Red                   Brush                 Epilux
        epoxy                                                                                                                       /                     78
        polyamide                                                                                                                   Spray
        primer
Interme High build 1                                              68                    100                   Grey    Brush                               Epilux
diate   epoxy                                                                                                         /                                   218HS
        polyamide                                                                                                     Spray
Finish  Gloss       1                                             50                    50                    White / Brush                               Robbiat
        Polyurethan                                                                                           Colours /                                   hane
        e                                                                                                             Spray
                    3                                                                   225

Touch up if required with Epilux 78 after power tool cleaning on spots




Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              164 of




System # 3, Exterior Surfaces –Concrete Masonry, Polyurethane Textured
Table 4
Coats                Generic                        # of          Solids                DFT                   Colour                Applicat Berger
                     Type                           coat          volume                Microns                                     ion      Product
                                                    s             %
Primer               Epoxy                          1             45                    50                    White                 Brush / Epilux
                     Concrete                                                                                                       Spray / Concret
                                                                                                                                    Roller   e
                                                                                                                                             Primer
Interme Epoxy        1                                            68                    1000                  White                 Hopper Luxatile
diate   spray                                                                                                                       Gun      Epoxy
        compound                                                                                                                             Spray
        in textured                                                                                                                          Compo
        finish                                                                                                                               und
Finish  Gloss      / 1                                            50                    50                    White                 Roller / Robbiat
        Semi Gloss                                                                                            /                     Spray    athane
        Polyurethan                                                                                           Colours
        e
                                                                                        1100

The textured pattern is unpressed and the DFT could vary from 700 to 1000
micron or more as manually applied by hopper gun
System # 4, Interior Surfaces –Galvanised Steel, Alkyd
Table 5
Coats                Generic                        # of Solids                         DFT                   Colour                Applicat Berger
                     Type                           coat volume                         Microns                                     ion      Product
                                                    s    %
Etch                 Two    Pack 1                                8.5                   5                     Greenish              Brush           / Luxaprim
Primer(T             washer                                                                                   Yellow                Spray             e 1500
o      be            primer
used in
surface
preparati
on
instead
of
blasting)
Primer               Anticorrosive 1                              55                    55                    Red                   Brush           / Luxaprim
Coat                 rust inhibitive                                                                                                Spray             e 1500
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              165 of




          Primer
Intermedi Alkyd                                     1             55                    55                    White   Brush                         / Luxole
ate Coat Undercoat                                                                                                    Spray                           1000
Finish    Alkyd Enamel                              1             48                    48                    White / Brush                         / Luxole
Coat                                                                                                          Colours Spray                           5000
                          4                155
Luxaprime 1000 has to be applied on the same day of Luxaprime 1500
System # 5, Interior Surfaces –Primed Ferrous Metal, Alkyd
Table 6
Coats                Generic                        # of Solids   DFT                                             Colour                Applicat Berger
                     Type                           coat volume % Microns                                                               ion      Product
                                                    s
Primer     High    build 1                                        50                        50                    Red              / Brush               / Luxaprim
Coat(If    alkyd    zinc                                                                                          Grey               Spray                 e 1400
required)  phosphate
           primer
Intermedi Alkyd          1                                        55                        50                    White   Brush                          / Luxol
ate Coat undercoat                                                                                                        Spray                            1000
Finish     Alkyd Enamel 1                                         50                        50                    White / Brush                          / Luxol
Coat                                                                                                              Colours Spray                            5000
Note-                    3                                                                  150
Primer
need not
be
applied if
already
primed




Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              166 of




System # 6, Interior Surfaces –Gypsum Wallboard and plaster, Acrylic
Table 7
Coats                Generic                        # of Solids                         DFT                   Colour                Applicat Berger
                     Type                           coat volume                         Microns                                     ion      Product
                                                    s    %
Primer               Premium                        1             25                    25                    White                 Brush   / Brolac
Coat                 quality alkali                                                                                                 Roller    Acrylic
                     resisting                                                                                                                AR
                     primer                                                                                                                   Primer
Filler               High quality           1(to                  81                    To        White                             Spatula   Berger
Coat                 acrylic based          seal                                        smoothe                                               Super
                     wall filler            &                                           n     the                                             Wall
                                            smo                                         surface                                               Filler
                                            othe
                                            n
                                            the
                                            surf
                                            ace)
Intermedi High                      quality 1                     35                    50                    White / Roller                              Bergerco
ate Coat acrylic                                                                                              Colours                                     at Acrylic
          emulsion                                                                                                                                        Emulsion
Finish    Semi    gloss 1                                         35                    50                    White / Roller                              Brolac
Coat      acrylic                                                                                             Colours                                     Semi
          emulsion                                                                                                                                        Gloss
                                                                                                                                                          Emulsion
                                                    3                                   >100




Method
GENERAL
Marking of containers
Materials shall be delivered in sealed containers clearly labelled with the following information.
Manufacturer‟s name, initials or recognised trade mark
Title and specification number
Whether primer or undercoat, finishing coat
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              167 of



Whether for internal or external use where appropriate
Colour reference from BS 4800
Method of application
Batch number and date of manufacture and re – test
No paint shall be used after 18 months of manufacture or re test
Coating materials other than spray paints, bituminous pants and fine textured masonry paint
shall be in containers not exceeding 5 litres capacity
Samples
Sample panel of 1 sqm in area shall be prepared for each type and colour of coating material
to be used in the work for the approval
Sample material of each paper / fibre material minimum size 500 x 500 mm showing at least
the pattern repeat where applicable shall be submitted for approval
Part 2
Materials
Preparatory Materials
Paint removers, abrasive papers and blocks, cleaning agents, etching solutions, stopping,
knotting, fillers and other commodities shall be of the types recommended by the manufacturer
of the coating to be applied
White spirit shall comply with BS 245
Knotting shall comply with BS 1336
Stopping and filler for woodwork shall be approved proprietary Leadless oil based type
recommended for internal or external work as appropriate. Stopping for woodwork to receive a
coat finish shall be tinted to match with the surrounding work
Filler for plaster or rendering shall be approved proprietary type
The following operational sequences shall be involved
Priming Coat
Filler Coat to the requirement
Intermediate Coat
Finishing Coat
All according to the approved system as aforesaid detailed for reference.
Application
PREPARATION OF THE GALVANIZED SURFACES
Dirt and other adherent contaminating matter / loose deposits shall be removed from
galvanised surfaces by mechanical means using Berger tool cleaner. Cleaning shall not
damage the galvanising. Oil or grease shall be removed from galvanised surfaces by the
application of an emulsion cleaner. Any zinc corrosion products remaining shall be removed by
washing with sweet water and scrubbing with hard bristle brushes
After being cleaned and degreased, all galvanised surfaces shall be etched with T-wash as
described in BS 5493. If any surface fails to turn black as cleaning, greasing and etching
processes shall be repeated.
APPLICATION OF PAINT GENERALLY
All paints shall be prepared and applied in strict accordance with the manufacturer‟s
instructions. Priming paints shall be applied by brush. Spray application shall only be used for
painting of epoxy resin base
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              168 of



Exposure of intermediate coats of paint for periods in excess of a few days shall not be
permitted except in case of work delivered to site in a primed condition
The dried films shall be free from bloom, shrinkage, sheeringness, wrinkling, sagging,
curtailing, discoloration and extraneous matter
No exterior or exposed paint work shall be carried out under adverse weather conditions,
during rain, mist, sandstorms nor when the relative humidity exceeds 80%
Painting shall insofar as is practicable be shaded from direct sunlight by netting to prevent
wrinkling and bristling. Whenever possible exterior painting shall be so programmed during the
day so as to be carried out in shadow
Painting of surfaces shall not be carried out when condensation is present on such surfaces or
the application and / or drying of the paints is likely to be affected
Surfaces to be painted shall receive as first coat of paint as quickly as possible after the e
preparation has been completed
In case of metal surfaces this shall preferably be within one hour but always before the metal
temperature drops to less than 3 deg C above dew point and before any rusting
METHOD OF COATING
Each coat shall be applied uniformly over the entire surface. Skips, runs, sags and drips shall
be avoided. When these occur they shall be brushed out immediately or the materials
removed and the surface recoated. On beams and irregular surfaces, edges shall be strip
coated first and at extra pass made later. Each coat shall be allowed to dry for the time
specified by the manufacturer before application of any succeeding coat
Any primer coat exposed to freezing, excess humidity, rain, dust etc., before drying, shall be
removed, surface again prepared and primed
The time interval between application of coats shall not exceed that specified for optimum
results by the manufacturer
All coatings shall be cleaned as specified by the manufacturer before the next coat is applied
All areas not specifically mentioned in the painting specification shall be finished to conform to
the adjacent comparable areas
All fixtures and surfaces not to be painted shall be properly protected during application and
upon completion of the work all paint and varnish removed from glass, fixtures, covering, etc.,
Moveable parts shall not to be painted.
All parts such as pipe supports, seatings and cleats, back to back sections which shall become
inaccessible after fabrication shall be treated on both surfaces with the full paint system prior to
final assembly, thus ensuring adequate protection.
SPRAY APPLICATION
All equipment for spray application shall be inspected and approved before any application
begins. Spray guns, hoses and pumps shall be cleaned before new material is added. An
adequate moisture and oil trap shall be installed between the air supply to each application
unit.
Suitable pressure regulators and gauges shall be provided for the air supply to the application
units. Spray equipment and operating pressures shall comply with the manufacturer‟s
recommendations.
Coating materials containing heavy pigments that have a tendency to settle shall be kept in
suspension during the application by the power driven, continuous agitator
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              169 of



The spray gun shall be held at right angles to the surface and each pass overlap the previous
one by approximately 50%. All materials contained herein may be applied by airless spray.
BRUSH APPLICATION
Brushes shall be of a style and quality that permit proper application of the material
Flat brushes shall not be more than 100 mm wide. No extending handles shall be used on
brushes.
Brushing shall be done so that a smooth coat as nearly uniform in thickness as possible is
obtained without any deep or detrimental marks
Paints shall be worked into all corners and crevices.
When applying solvent type coating, care shall be taken to prevent lifting of previous coats.
FILM THICKNESS
Specified film thickness for coating materials shall be strictly observed which be checked with
an appropriate film thickness gauge. Calibration for the thickness range to be checked at least
twice a day
When dry film thickness are less than those specified, additional coats shall be applied as
required. Particular attention shall be paid to full film thickness on edges
In hot weather such additional precautions as are necessary shall be taken to ensure that the
specified dry film thickness on priming or finish coats is obtained
COATING QUALITY
Coatings shall be free from pinholes, voids, bubbles, dust, foreign inclusions and other
holidays and any such defect shall be repaired. Prior to the application of a coating, any
damage to the previous coating shall be repaired with the specified material. Upon completion
of the fabrication any damage to the coating system shall be repaired
TEST EQUIPMENT
Svensk photographic standard SIS 05 59 00
Coating thickness meter such as Elcometer „Minitector” Model 150
Wet fill thickness combs
Hygrometer
Maximum and minimum thermometer
Flow cup type B # 4 and timer
Surface profile meter such as Elcometer‟Roughness detector‟
Bolted site connections other than faying surfaces of Grip Bolt connections shall be brought
together „wet‟
EPOXY COATING WORK GENERALLY
In addition to the general requirements the following conditions shall apply wherever epoxy-
coating work is being carried out
Forced draught ventilation shall be used wherever required for the needs of the personnel or
for drying out surfaces
Operatives shall work in pairs
Samples areas on substrate shall be prepared and coated for approval
There shall be strict control of surface cleanliness between primer and epoxy coating / and
between coats of the same. Vacuum removal of dust and sand shall be employed and
contamination removed. Where dirt or dust has been trapped in the painted surface it shall be

Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              170 of



removed with suitable abrasive paper. The surface being painted shall be free of visible
moisture throughout these operations
The paint shall be applied only to the clean dry primed or previously coated surfaces. Any thick
runs or collections of paint shall be removed before these harden
Not less than 2 coats shall be applied over the primer by airless spray, less than 3 by brush
Each coat shall be distinctly different in colour from the primer or previous coat. The colour of
the final coat shall be as approved. Each coat shall be seen to have completely covered the
proceeding without „ misses‟ or pinholes or any areas visibly low in thickness. A high voltage
pinhole detector shall also be used to determine the integrity of the coats
The manufacturer of the coating shall stipulate primer and epoxy recoat interval for all curing
temperatures likely to be encountered and these be adopted with a maximum tolerance of +4
hours. Where this is exceeded, the surfaces to be recoated shall first be suitably abraded to
remove gloss and provide a key
Wet thickness gauges shall be used by the coating operators continually to check that
sufficient paint is being applied to achieve the desired dry film thickness
EPOXY COATING FOR CONCRETE AND RENDERED SURFACES
No priming shall commence until the moisture content of the cementitious surface is less than
5% measured by Wetcheck Moisture meter or other instrument
Similarly moisture measurements over the primer or any epoxy intercoat shall not exceed 1 %
on the concrete scale of the instrument when the probe tips are held against such painted
surfaces just prior to recoating
The priming shall be applied by suitable Nylon bristle brush or spray over the whole area to be
coated at such thickness that it may then be squeezed into the pores of the concrete. Any
excess shall be removed by the most suitable means before application of the high build epoxy
The total DFT of the paint layer shall have a minimum specified value
Whenever the paint inspection gauge has been used and wherever the coating has been
otherwise damaged for 50 mm around such damage, the surfaces shall be abraded followed
by the area touched in with not less than 2 # thick applications to restore the coating integrity
to the specified thickness.
Adhesion tests shall be carried out on the cured coating surface using the test equipment
supplied in accordance with the best practice. The resulting test specimens shall show no
indication of poor adhesion to the substrate, residual laitance or intercoat adhesion weakness.
The following instrument shall be used
1 Adhesion Tester 0 to 35 kg / cm2
1 DC high voltage holiday detector # 105
One paint inspection gauge PIG
1 wet check moisture meter
#72


Painting
Administration building
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              171 of




Top

Index
Scope
Reference documents
Definitions
Responsibilities
Safety
Method
Equipment
Attachment
Scope
This statement is aimed to present the proposed procedures that shall be adopted to apply the
Painting System on the above building on various surfaces according to the specifications and
the material system approved.
References
Specifications
MAR #
Definitions
PSM           Project Site Manager
CSM           Construction Manager
CS            Construction Superintendent
FM            Foreman
QC            Quality Control
Responsibilities
PSM shall control the overall operations
CM shall arrange the resources required accordingly
CS shall control, monitor and direct the FM and workforce for the operations
FM shall execute the operations deploying the workforce
QC shall inspect all the operations according to the specifications
EPC Contractor shall conduct surveillance
Safety
Prior to the commencement of work, the labour force shall receive a Toolbox talk relevant to
the operation concerned to the Project Site Safety requirements.
Any process that is adopted which may have a particular Safety risk shall be assessed to the
requirement for Site conditions and be taken care of.
The personnel shall use the PPE, gloves, masks, eyeglasses etc and to avoid skin contact.
use of barrier cream shall also be made.
Material safety data shall be referred to for disposal and any further information.
Adequate arrangement shall be made to provide access to the top of the wall.
Adequate scaffolding with proper netshade shall be provided wherever required
The personnel shall use the waist safety belt / harness while working on height.
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              172 of



Immediate medical care shall be provided in case the eyes of any personnel are effected due
to the paint splashes or any other reason
Proper ventilation shall be provided to let the workers respirate properly
A safety inspector shall visit the site every day and instruct the supervisor in case any snag is
observed who immediately implement the instructions accordingly.
Storage
The material shall be stored under cover out of direct sunlight and protected from extreme
temperatures. Shelf life 12 months between 5 deg and 35 Celsius
Materials
Berger Paint systems
MAR #

Table 8
S # Sub Strata                                           Surface preparation                                            Operating
                                                                                                                        temperature
1           Galvanised        steel-                     Mechanical cleaning                             to      remove Upto 100 deg C
            Exterior,Polyurethane                        loose deposits
2           Mild      steel-Exterior,                    Blasting to Sa 2.5                                                         Upto 100 deg C
            Polyurethane
3           Concrete        Surface-                     Cleaning with sand stone to Upto 100 deg C
            Exterior,                                    smoothen the surface free from all
            Polyurethane                                 dirt etc
            textured
4           Galvanised        Steel-                     Mechanical cleaning to remove Upto 60 deg C
            Interior, Alkyd                              loose deposits
5           Galvanised        Steel-                     Mechanical cleaning to St 2 to Upto 60 deg C
            Interior,        Primed                      remove loose rust, scales
            ferrous metal Alkyd
6           Plaster and Gypsum-                          Cleaning with fine emery paper to Upto 50 deg C
            Gypsum wall board                            remove dirt etc.
            and plaster, Acrylic




Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              173 of




System # 1, Exterior Surfaces –Galvanised Steel, Polyurethane
Table 9
Coats   Generic       # of Solids   DFT      Colour Applicat                                                                                              Berger
        Type          coat volume Microns             ion                                                                                                 Product
                      s    %
Primer Surface        1    82       100      Alumini Brush /                                                                                              Epimast
        tolerant                             um       Spray                                                                                               ic 5100
        high build                                                                                                                                        Al
        epoxy
Finish  Gloss         1    50       50       White / Brush /                                                                                              Robbiat
        Polyurethan                          Colours Spray                                                                                                hane
        e
                      2             150

System # 2, Exterior Surfaces –Ferrous Metal, Polyurethane
Table 10
Coats                Generic                # of                  Solids                DFT                   Colour                Applicat Berger
                     Type                   coat                  volume                Microns                                     ion      Product
                                            s                     %
Primer  High                          build 1                     57                    75                    Red                   Brush                 Epilux
        epoxy                                                                                                                       /                     78
        polyamide                                                                                                                   Spray
        primer
Interme High build 1                                              68                    100                   Grey    Brush                               Epilux
diate   epoxy                                                                                                         /                                   218HS
        polyamide                                                                                                     Spray
Finish  Gloss       1                                             50                    50                    White / Brush                               Robbiat
        Polyurethan                                                                                           Colours /                                   hane
        e                                                                                                             Spray
                    3                                                                   225

Touch up if required with Epilux 78 after power tool cleaning on spots




Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              174 of




System # 3, Exterior Surfaces –Concrete Masonry, Polyurethane Textured
Table 11
Coats                Generic                        # of          Solids                DFT                   Colour                Applicat Berger
                     Type                           coat          volume                Microns                                     ion      Product
                                                    s             %
Primer               Epoxy                          1             45                    50                    White                 Brush / Epilux
                     Concrete                                                                                                       Spray / Concret
                                                                                                                                    Roller   e
                                                                                                                                             Primer
Interme Epoxy        1                                            68                    1000                  White                 Hopper Luxatile
diate   spray                                                                                                                       Gun      Epoxy
        compound                                                                                                                             Spray
        in textured                                                                                                                          Compo
        finish                                                                                                                               und
Finish  Gloss      / 1                                            50                    50                    White                 Roller / Robbiat
        Semi Gloss                                                                                            /                     Spray    athane
        Polyurethan                                                                                           Colours
        e
                                                                                        1100

The textured pattern is unpressed and the DFT could vary from 700 to 1000
micron or more as manually applied by hopper gun

System # 4, Interior Surfaces –Galvanised Steel, Alkyd
Table 12
Coats                Generic                        # of Solids                         DFT                   Colour                Applicat Berger
                     Type                           coat volume                         Microns                                     ion      Product
                                                    s    %
Etch                 Two    Pack 1                                8.5                   5                     Greenish              Brush           / Luxaprim
Primer(T             washer                                                                                   Yellow                Spray             e 1500
o      be            primer
used in
surface
preparati
on
instead
of
blasting)
Primer               Anticorrosive                  1             55                    55                    Red                   Brush           / Luxaprim
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
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                                                                                                                                              175 of




Coat      rust inhibitive                                                                                                           Spray                 e 1500
          Primer
Intermedi Alkyd           1                                       55                    55                    White   Brush                         / Luxole
ate Coat Undercoat                                                                                                    Spray                           1000
Finish    Alkyd Enamel 1                                          48                    48                    White / Brush                         / Luxole
Coat                                                                                                          Colours Spray                           5000
                          4                                                             155

Luxaprime 1000 has to be applied on the same day of Luxaprime 1500


System # 5, Interior Surfaces –Primed Ferrous Metal, Alkyd
Table 13
Coats                Generic                        # of Solids   DFT                                             Colour                Applicat Berger
                     Type                           coat volume % Microns                                                               ion      Product
                                                    s
Primer     High    build 1                                        50                        50                    Red              / Brush               / Luxaprim
Coat(If    alkyd    zinc                                                                                          Grey               Spray                 e 1400
required)  phosphate
           primer
Intermedi Alkyd          1                                        55                        50                    White   Brush                          / Luxol
ate Coat undercoat                                                                                                        Spray                            1000
Finish     Alkyd Enamel 1                                         50                        50                    White / Brush                          / Luxol
Coat                                                                                                              Colours Spray                            5000
Note-                    3                                                                  150
Primer
need not
be
applied if
already
primed




Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              176 of




System # 6, Interior Surfaces –Gypsum Wallboard and plaster, Acrylic
Table 14
Coats                Generic                        # of Solids                         DFT                   Colour                Applicat Berger
                     Type                           coat volume                         Microns                                     ion      Product
                                                    s    %
Primer               Premium                        1             25                    25                    White                 Brush   / Brolac
Coat                 quality alkali                                                                                                 Roller    Acrylic
                     resisting                                                                                                                AR
                     primer                                                                                                                   Primer
Filler               High quality           1(to                  81                    To        White                             Spatula   Berger
Coat                 acrylic based          seal                                        smoothe                                               Super
                     wall filler            &                                           n     the                                             Wall
                                            smo                                         surface                                               Filler
                                            othe
                                            n
                                            the
                                            surf
                                            ace)
Intermedi High                      quality 1                     35                    50                    White / Roller                              Bergerco
ate Coat acrylic                                                                                              Colours                                     at Acrylic
          emulsion                                                                                                                                        Emulsion
Finish    Semi    gloss 1                                         35                    50                    White / Roller                              Brolac
Coat      acrylic                                                                                             Colours                                     Semi
          emulsion                                                                                                                                        Gloss
                                                                                                                                                          Emulsion
                                                    3                                   >100

Method
GENERAL
Marking of containers
Materials shall be delivered in sealed containers clearly labelled with the following information.
Manufacturer‟s name, initials or recognised trade mark
Title and specification number
Whether primer or undercoat, finishing coat
Whether for internal or external use where appropriate
Colour reference from BS 4800
Method of application
Batch number and date of manufacture and re – test
No paint shall be used after 18 months of manufacture or re test
Coating materials other than spray paints, bituminous pants and fine textured masonry paint
shall be in containers not exceeding 5 litres capacity


Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
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Samples
Sample panel of 1 sqm in area shall be prepared for each type and colour of coating material
to be used in the work for the approval
Sample material of each paper / fibre material minimum size 500 x 500 mm showing at least
the pattern repeat where applicable shall be submitted for approval
Part 2
Materials
Preparatory Materials
Paint removers, abrasive papers and blocks, cleaning agents, etching solutions, stopping,
knotting, fillers and other commodities shall be of the types recommended by the manufacturer
of the coating to be applied
White spirit shall comply with BS 245
Knotting shall comply with BS 1336
Stopping and filler for woodwork shall be approved proprietary Leadless oil based type
recommended for internal or external work as appropriate. Stopping for woodwork to receive a
coat finish shall be tinted to match with the surrounding work
Filler for plaster or rendering shall be approved proprietary type
The following operational sequences shall be involved
Priming Coat
Filler Coat to the requirement
Intermediate Coat
Finishing Coat
All according to the approved system as aforesaid detailed for reference.
Application
PREPARATION OF THE GALVANIZED SURFACES
Dirt and other adherent contaminating matter / loose deposits shall be removed from
galvanised surfaces by mechanical means using Berger tool cleaner. Cleaning shall not
damage the galvanising. Oil or grease shall be removed from galvanised surfaces by the
application of an emulsion cleaner. Any zinc corrosion products remaining shall be removed by
washing with sweet water and scrubbing with hard bristle brushes
After being cleaned and degreased, all galvanised surfaces shall be etched with T-wash as
described in BS 5493. If any surface fails to turn black as cleaning, greasing and etching
processes shall be repeated.
APPLICATION OF PAINT GENERALLY
All paints shall be prepared and applied in strict accordance with the manufacturer‟s
instructions. Priming paints shall be applied by brush. Spray application shall only be used for
painting of epoxy resin base
Exposure of intermediate coats of paint for periods in excess of a few days shall not be
permitted except in case of work delivered to site in a primed condition
The dried films shall be free from bloom, shrinkage, sheeringness, wrinkling, sagging,
curtailing, discoloration and extraneous matter
No exterior or exposed paint work shall be carried out under adverse weather conditions,
during rain, mist, sandstorms nor when the relative humidity exceeds 80%

Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
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Painting shall insofar as is practicable be shaded from direct sunlight by netting to prevent
wrinkling and bristling. Whenever possible exterior painting shall be so programmed during the
day so as to be carried out in shadow
Painting of surfaces shall not be carried out when condensation is present on such surfaces or
the application and / or drying of the paints is likely to be affected
Surfaces to be painted shall receive as first coat of paint as quickly as possible after the e
preparation has been completed
In case of metal surfaces this shall preferably be within one hour but always before the metal
temperature drops to less than 3 deg C above dew point and before any rusting
METHOD OF COATING
Each coat shall be applied uniformly over the entire surface. Skips, runs, sags and drips shall
be avoided. When these occur they shall be brushed out immediately or the materials
removed and the surface recoated. On beams and irregular surfaces, edges shall be strip
coated first and at extra pass made later. Each coat shall be allowed to dry for the time
specified by the manufacturer before application of any succeeding coat
Any primer coat exposed to freezing, excess humidity, rain, dust etc., before drying, shall be
removed, surface again prepared and primed
The time interval between application of coats shall not exceed that specified for optimum
results by the manufacturer
All coatings shall be cleaned as specified by the manufacturer before the next coat is applied
All areas not specifically mentioned in the painting specification shall be finished to conform to
the adjacent comparable areas
All fixtures and surfaces not to be painted shall be properly protected during application and
upon completion of the work all paint and varnish removed from glass, fixtures, covering, etc.,
Moveable parts shall not to be painted.
All parts such as pipe supports, seatings and cleats, back to back sections which shall become
inaccessible after fabrication shall be treated on both surfaces with the full paint system prior to
final assembly, thus ensuring adequate protection.
SPRAY APPLICATION
All equipment for spray application shall be inspected and approved before any application
begins. Spray guns, hoses and pumps shall be cleaned before new material is added. An
adequate moisture and oil trap shall be installed between the air supply to each application
unit.
Suitable pressure regulators and gauges shall be provided for the air supply to the application
units. Spray equipment and operating pressures shall comply with the manufacturer‟s
recommendations.
Coating materials containing heavy pigments that have a tendency to settle shall be kept in
suspension during the application by the power driven, continuous agitator
The spray gun shall be held at right angles to the surface and each pass overlap the previous
one by approximately 50%. All materials contained herein may be applied by airless spray.
BRUSH APPLICATION
Brushes shall be of a style and quality that permit proper application of the material
Flat brushes shall not be more than 100 mm wide. No extending handles shall be used on
brushes.
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
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                                                                                                                                              179 of



Brushing shall be done so that a smooth coat as nearly uniform in thickness as possible is
obtained without any deep or detrimental marks
Paints shall be worked into all corners and crevices.
When applying solvent type coating, care shall be taken to prevent lifting of previous coats.
FILM THICKNESS
Specified film thickness for coating materials shall be strictly observed which be checked with
an appropriate film thickness gauge. Calibration for the thickness range to be checked at least
twice a day
When dry film thickness are less than those specified, additional coats shall be applied as
required. Particular attention shall be paid to full film thickness on edges
In hot weather such additional precautions as are necessary shall be taken to ensure that the
specified dry film thickness on priming or finish coats is obtained
COATING QUALITY
Coatings shall be free from pinholes, voids, bubbles, dust, foreign inclusions and other
holidays and any such defect shall be repaired. Prior to the application of a coating, any
damage to the previous coating shall be repaired with the specified material. Upon completion
of the fabrication any damage to the coating system shall be repaired
TEST EQUIPMENT
Svensk photographic standard SIS 05 59 00
Coating thickness meter such as Elcometer „Minitector” Model 150
Wet fill thickness combs
Hygrometer
Maximum and minimum thermometer
Flow cup type B # 4 and timer
Surface profile meter such as Elcometer‟Roughness detector‟
Bolted site connections other than faying surfaces of Grip Bolt connections shall be brought
together „wet‟
EPOXY COATING WORK GENERALLY
In addition to the general requirements the following conditions shall apply wherever epoxy-
coating work is being carried out
Forced draught ventilation shall be used wherever required for the needs of the personnel or
for drying out surfaces
Operatives shall work in pairs
Samples areas on substrate shall be prepared and coated for approval
There shall be strict control of surface cleanliness between primer and epoxy coating / and
between coats of the same. Vacuum removal of dust and sand shall be employed and
contamination removed. Where dirt or dust has been trapped in the painted surface it shall be
removed with suitable abrasive paper. The surface being painted shall be free of visible
moisture throughout these operations
The paint shall be applied only to the clean dry primed or previously coated surfaces. Any thick
runs or collections of paint shall be removed before these harden
Not less than 2 coats shall be applied over the primer by airless spray, less than 3 by brush
Each coat shall be distinctly different in colour from the primer or previous coat. The colour of
the final coat shall be as approved. Each coat shall be seen to have completely covered the
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
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                                                                                                                                              180 of



proceeding without „ misses‟ or pinholes or any areas visibly low in thickness. A high voltage
pinhole detector shall also be used to determine the integrity of the coats
The manufacturer of the coating shall stipulate primer and epoxy recoat interval for all curing
temperatures likely to be encountered and these be adopted with a maximum tolerance of +4
hours. Where this is exceeded, the surfaces to be recoated shall first be suitably abraded to
remove gloss and provide a key
Wet thickness gauges shall be used by the coating operators continually to check that
sufficient paint is being applied to achieve the desired dry film thickness
EPOXY COATING FOR CONCRETE AND RENDERED SURFACES
No priming shall commence until the moisture content of the cementitious surface is less than
5% measured by Wetcheck Moisture meter or other instrument
Similarly moisture measurements over the primer or any epoxy intercoat shall not exceed 1 %
on the concrete scale of the instrument when the probe tips are held against such painted
surfaces just prior to recoating
The priming shall be applied by suitable Nylon bristle brush or spray over the whole area to be
coated at such thickness that it may then be squeezed into the pores of the concrete. Any
excess shall be removed by the most suitable means before application of the high build epoxy
The total DFT of the paint layer shall have a minimum specified value
Whenever the paint inspection gauge has been used and wherever the coating has been
otherwise damaged for 50 mm around such damage, the surfaces shall be abraded followed
by the area touched in with not less than 2 # thick applications to restore the coating integrity
to the specified thickness.
Adhesion tests shall be carried out on the cured coating surface using the test equipment
supplied in accordance with the best practice. The resulting test specimens shall show no
indication of poor adhesion to the substrate, residual laitance or intercoat adhesion weakness.
The following instrument shall be used
1 Adhesion Tester 0 to 35 kg / cm2
1 DC high voltage holiday detector # 105
One paint inspection gauge PIG
1 wet check moisture meter

#73




Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
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                                                                                                                                              181 of




Road crossing for laying 2 pipes
1 for 20” raw ethane
&
1 for 6”propane
Avenue „c‟
Top

Index
Scope
Reference documents
Definitions
Responsibilities
Safety
Method including traffic management scheme
Equipment
Attachment
Scope
The statement is aimed to propose the procedures to be adopted to carry out the excavation at
the road crossing to facilitate to lay the pipe lines 1 # each 20” Raw Ethane and 6” Propane at
locations identified on the attached drawing to the following references
Reference documents
Specification Excavation & Backfilling for Underground structures.
Drawing No.
Easement Systems Avenue “C”
Piping Interconnection Drawings, Avenue „C‟
Definitions
PSM           Project Site Manager
CSM           Construction Manager
CS            Construction Superintendent
SE            Site Engineer
FM            Foreman
QC            Quality Control
Responsibilities
PSM shall control the overall operations
CM shall arrange the resources required accordingly and be overall responsible for the
excavation operation
CS shall control, monitor and direct the SE, FM and workforce for the operations
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
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SE shall be responsible for all the site operations and follow the instructions of the CS
Any mishap on the excavation operation shall immediately be notified to the CS and the CM for
the immediate action if so required for any possible remedy or record or the authority review
whatsoever,the case may be
FM shall execute the operations deploying the workforce. FM shall explain in full in the
language the work persons understand about all the instruction and the ToolBox talks every
day and check that the same are followed up regularly
QC shall inspect all the operations according to the specifications
EPC Contractor shall conduct surveillance
Safety
Prior to the commencement of any activity the labour force shall receive a Toolbox talk
relevant to the operation concerned on the project site safety requirements. Any process is
adopted having a particular safety risk shall be assessed and addressed as required to raise to
a minimum standard / an acceptable mark.
In the present case the excavation has to be carried out on the Operating Authority area,
therefore all the regulated precautions shall be resorted to effect a full safety standard.
ToolBox Talks-
While conducting ToolBox Talks, a representative from the authority shall be involved to
witness and sign the instruction imparted with the workers prior to the commencement of the
operations to make a record. Only English literate Foreman shall be employed to work on
the excavation execution.
Excavation Work Permit- A copy of the work permit shall be posted on a mini board installed
on site to be noticeable to all the relevant persons involved on the crossing
Traffic Management-Sign boards keep up-All the personnel shall be briefed about the safe
keep up of the boards
Barricades,cones, markers and the night-lights, flood lights etc. shall be arranged as
required for a complete safety. No oil spillage shall be allowed.
The sides of the excavation shall be sloped with the barriers placed to indicate the excavation
work in progress
Flagman-On both the direction, in addition to the traffic sign boards, a flagman shall be
engaged to operate full time to direct the traffic about the excavation work in progress by
waving the flag for all the vehicles passing by
Hand Excavation- Excavation required to be by hand shall only be carried out manually. In
case certain services not shown on the record drawings such as fibre optics cable is
discovered, the excavation shall be ceased to be continued until the decision to hydrojetting
is taken up and the authority are involved.
Jack Hammer- The worker engaged on operating this equipment shall use protective glass
and work in phases with pause intervals. The compressor air pressure shall be monitored from
time to time so that the hammer works smoothly. The compressor shall be place within the
barricade limits
Access to trench- The workers shall clearly be instructed to use only the ladders to enter in or
come out. No jumping shall be allowed
Machine Excavation

Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
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The operators shall be explicitly explained and instructed about the requirement of the reverse
signal and sound when operating reverse. The truck driver shall also be instructed similarly.
Banksman shall be engaged while the equipment operate.
No violation of the traffic rules shall be allowed
Deep Trenches
If required, the shoring shall be provided to prevent the caving in. In case of the trench depth
being more than 1200 mm. Adequate means of exit such as Aluminium ladder or steps shall
be provided and located no more than 8 m of lateral travel.
Plants preservation
The live plants and the trees arboricultured shall be deplanted integrally with the roots and
preserved to the specialist requirement so that these remain live till the replantation is carried
out all to the satisfaction of the specialist
Safety Supervision
A competent inspector shall inspect the trench daily to assess the safety measures adopted.
Method
The required permit to work shall be obtained from the Plant Refinery Division.
The record drawings regarding the existing services shall be obtained.

A traffic management scheme has been presented herein and shall be produced on site as
detailed on the attached sketch for this road crossing which includes, reduced speed sign,
temporary diverted roads sign, men at work sign, warning signs, informatory signs, safety
barriers, night lighting and road cleaning activities etc.
The traffic management scheme shall be reviewed and approved by EPC Contractor prior to
commencing the work.
The aforesaid traffic management scheme shall be implemented as described below:
TRAFFIC MANAGEMENT SCHEME ROAD CROSSING – First Street / Avenue „C‟
Drawing reference –24168-P40-310-00005 Rev O
This proposed crossing is located on the Road Avenue „C‟ between the following
Co-ordinates as shown on the referred drawing.
This is a 2-way road with a central verge and carrying 2 lanes on either way
The proposed crossing is located about 160 m from 1st street road towards North
One serving electric pole is located away from the x-ing
The minor irrigation / hoses are serving on the central verge
Some minor trees and plants are arboricultured on the central verge.
The road shall be divided in 2 parts as shown on the sketch as lane L1 and L 2 on either side
of the carriageway.
In the first instance the work shall be carried out on part L1 diverting the traffic to the road
portion on the part L2 as shown on the sketch.
In the second instance the work shall be carried out on part L2 diverting the traffic to the road
portion on the completed road portion on the part L1 as shown on the sketch.
The directory signboards shall also be placed on the 1 st street road East West on both ways to
indicate the work at the crossing
For the traffic North to South the first reduce speed for traffic diversion informatory board
depicting shall be located at 300 m from the point of the proposed crossing, the second
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
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                                                                                                                                              184 of



depicting diversion signs be located at 200 m and the third depicting men at work sign be
located at 100 m on either way in the opposite directions.
For the traffic South to North past crossing, one sign shall be placed to direct for the diversion,
to slow down and the men at work ahead
A Flagman shall be engaged full time on both the directions to guide the traffic about the
ongoing excavation operations in addition to the conventional signboards
The following activities are involved. Reference to the marked note „B‟ on the
Easement Systems Drawing
To produce the Traffic Diversion Management Scheme
To excavate by hand and expose all the underground facilities
5.5KV / 0.24KV cables are available
Trial pits to be excavated in size 5mx2mx1.5m deep by hand tools
To seam the area with the detectors to ascertain the access to the cable
To expose the cable fully and to be inspected by the authorities / Operating Authority
After the exposure, all the cables to be covered with split PVC pipe to continue the excavation
mechanically according to the authority directions and as agreed
To excavate the remaining portion by the excavator machine
To have authority inspection
The pipes to be laid by others
To fill the bedding material according to the specification requirement
To reinstate the diverted services
To reinstate the central verge to the existing state
Details
The Traffic Management Scheme shall be executed as explained in the foregoing and to the
traffic manual directions.
The first section of the proposed road crossing as per the attached sketch shall be marked by
the surveyor on the actual location. Any existing services shall be identified from the Record
drawings and measures to protect resorted to according to the regulations.
The asphalt shall be cut using jackhammers
The road section shall be excavated to the existing cables manually for which the trial pit may
be made prior to the full manual excavation is proceeded and after ascertaining the safe
procedures the exposures be completed.
After the exposure of the cables, the Operating Authority authorities shall inspect and the
cables be diverted accordingly following which the remaining machine excavation be carried
out to the specified levels
The excavated material shall be removed from the site to stockpile area.
Appropriate bedding material shall be placed within the excavated trench to the correct service
level. Where required, this bedding shall be compacted and tested.
The excavated trench shall be inspected by the authorities as required.
The potable and the Desalinated water pipes shall be laid by others.
Backfill around the service pipes shall be carried using the appropriate material.
The service pipes surrounding material shall be compacted as per the project specification
requirements. Test results shall be provided for the specification conformance verification.
The existing services shall be reinstated accordingly.
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              185 of



The plants or trees if removed and so required, shall be reinstated accordingly.
General fill up to the underside of road formation shall be placed in 150mm compacted layers
using mechanical methods to the specification requirements.
A concrete slab shall be cast up to the bottom of the finished asphalt level.
The finishing shall be carried out using approved asphalt mix.
The traffic management system shall be removed after the road crossing has been cleaned of
any debris or obstructions.
Either side of the road shall be provided with cable markers to indicate the services
Major Equipment
Excavator.Dump trucks.Compactors.
Jack Hammer, Compressor,
Attachment
Sketch showing the traffic management scheme
Drawings including the traffic diversion
#74
Earthworks survey system
Top

Index
Scope
Reference documents
Definitions
Responsibilities
Safety
Method
Equipment
Attachment
Scope
The purpose of this method statement, is to define the procedure that shall be adopted for the
control of the site earthwork activities.
Reference documents
Method statement. Site Preparation & Earthworks.
Specification Site Preparation.
Definitions
EPC Contractor
Civil Contractor .
PSM Project Site Manager.
IS      Infrastructure Superintendent.
ST     Survey team.
QM Quality Manager.
RFI     Request for Inspection.

Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              186 of




Responsibilities
The PSM shall ensure the implementation of this method statement upon the earthworks
activities.
The IS shall coordinate and supervise the implementation of this method statement by the ST
on a day to day basis.
Safety
The Safety Officer shall monitor the daily earthworks activities, advising and implementing all
safety procedures.
Method
Where areas are to be grubbed, the IS shall direct the ST to establish grid stakes, at 50m
centers, within the area to be grubbed. The ST, prior to the commencement of the machine
activities shall provide a sketch of the area defining the outer Northings and Eastings of the
area.
Upon completion of the establishment of the survey grid stakes and the site sketch, the IS shall
inform the QM.
The QM shall inspect the area to verify the correct establishment of the survey grid stakes.
The QM shall notify the EPC Contractor Engineer of the proposed grubbing activity by using
the RFI notification system.
The EPC Contractor Engineer shall review the proposed grubbing area. Should the EPC
Contractor Engineer have any comments or observations about the area, he shall inform the
QM and / or IS of these observations. The appropriate actions shall be conducted.
Upon completion of the grubbing activity, the IS shall notify the QM, who shall inspect the area
and complete the appropriate RFI.
The EPC Contractor Engineer shall review the area with the QM and Geotechnical Engineer,
and comment if appropriate.
Where the area requires to be “cut”‟ the ST shall establish pegs to indicate the correct cut
level. The cut activity shall be conducted.
Upon completion of the “cut” activity, the ST shall produce a ground level survey of the cut
area. This survey shall be forwarded to the QM for record purposes. The QM shall transmit a
copy of the survey report to the EPC Contractor Engineer.
Where the area requires a “fill” activity, the formation level shall be moisturized and compacted
as defined within the earthworks method statement. The IS shall coordinate with the ST to
establish fill stakes, that shall indicate the layer levels. Each fill layer shall be placed,
moisturized and compacted according to the earthworks method statement.
Upon completion of all the fill layers to the area, the ST shall produce a survey of finished
ground levels. This survey shall be forwarded to the QM for record. A copy of this survey shall
be transmitted to the EPC Contractor Engineer.
Should a grubbing level stake or fill stake be damaged or moved, the ST shall re establish the
stake correctly.
The RFI system shall document the comments and observations of an activity by the EPC
Contractor engineer.
Equipment
Total station distomat.
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              187 of



Stakes.
Marker tape.
Attachment
None.

#75

Road crossing for laying
84”GRE pair seawater
Cooling lines
At
Avenue „d‟ / corniche
Junction
Top


Index
Scope
Reference documents
Safety
Method including traffic management scheme
Equipment
Attachment
Scope
The statement is aimed to propose the procedures to be adopted to carry out the excavation at
the road to facilitate to lay the pipe lines 1 # pair 84” GRE Sea Water Cooling supply lines at
Avenue‟D‟ and „Cornice Road‟ junction identified on the attached drawing to the following
references
Reference documents
Specification. Excavation & Backfilling for Underground structures.
Drawing No.
Piping Interconnection Drawings- SeaWater Cooling Supply Lines
Safety
Prior to the commencement of any activity the labour force shall receive a / STARRT card /
Toolbox talk. Any process involving a particular safety risk shall be assessed and adopted
measures addressed to raise to a minimum standard

Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              188 of



In this case the excavation has to be carried out on the Operating Authority area, therefore all
the regulated precautions shall be strictly adhered to effect „ full safety standard‟.
Safety Supervision
A competent inspector shall visit the area daily to assess the safety measures adopted. Any
snag observed during his visit shall be notified to the supervisor present who immediately act
to bring the safety measures to an acceptable standard
In case of incident where utilities not identified are discovered or damaged, all work shall stop
in the area and the Operator Shift Controller and HSE department immediately notified
Phone number :
Shift Controller
Emergency Number
HSE Direct number
Employees working in easement area shall have a daily pre-task briefing that includes;
Reporting of incidents
Methods of work and tools to be used
Potential hazards found in the Easement areas
The approved work method statement
EPC Contractor and Civil Contractor HSE department shall participate in presenting the
STARRT card briefing and monitor the activities to ensure that the work methods are being
followed and all personnel have an understanding of the hazards associated with working
adjacent to live process areas
Excavation Work Permit- A copy of the work permit shall be posted on a mini board installed
on site to be noticeable to all persons involved with the crossing
Barricades, cones, markers, the night-lights, and floodlights etc. shall be installed as required
for a complete safety. No oil spillage shall be allowed.
Flagman-On all directions, in addition to the traffic sign boards, a flagmen shall be engaged
full time to direct the traffic about the „excavation work in progress‟ by „flag signal‟
Hand Excavation- Excavation to expose the services shall be carried out manually.
In case certain services not shown on the record drawings such as fibre optics but it is
discovered, further excavation shall be ceased until a decision is taken for the method to be
adopted for further excavation
Access to trench- The workers shall clearly be instructed to use only the ladders to enter in
or come out of the trench. No jumping shall be allowed
Machine Excavation
The operators / drivers shall be explicitly instructed to abide by the requirement of the reverse
signal and sound when operating reverse. Banksman shall be engaged equipment operation.
No violation of the traffic rules shall be allowed
Method
Corniche Road / Avenue „D Junction‟
Avenue „D‟ is a 2-way road carrying single lane on either way
Corniche Street is a 2-way road with a central verge, carrying 2 lanes on either way on the
West direction and without a central verge but single lane on the Eastern direction.
The essential permit to work shall be obtained from the Refinery Division.
The record drawings pertaining to the existing services shall be obtained.
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              189 of



A traffic management scheme has been presented herein and shall be produced on site as
detailed on the attached sketch for this road crossing
Pumping out water shall be carried out continuously in case it is necessary
Existing Services
2 # serving electric poles are located one at the curve and the other in the Northern central
verge which shall be effected by the proposed trench as the excavation line is expected to
pass through the verge and the general impacts shall be to the extent of,
“The central verge partly, the island partly, guard rail fully about 30 m with channels, Corniche
street sign board, Kerb stones”
The road shall be divided in 2 parts on either side of the carriageway.
First Instance
The first section covering the length of one pipe to be connected to the existing pipeline at
South of the proposed road crossing shall be marked on the actual location.
The work shall be carried out on part 1 diverting the traffic to the road portion on part 2 and on
the existing natural ground at South as shown on the sketch.
The asphalt shall be cut using jackhammers
The road section shall be excavated to the existing cables manually and the existence of the
cables confirmed by the use of seaming. After the exposure of the cables, the Operating
Authority authorities shall be invited to inspect and the cables diverted accordingly
The cables shall be protected by PVC split pipe and covered, supported well temporarily. The
machine excavation shall be carried out to the final levels.
The excavated material shall be removed from the site to stockpile area.
Appropriate bedding material shall be placed within the excavated trench to the correct service
level, compacted and tested.
The excavated trench shall be inspected by EPC Contractor
The GRE pipes shall be laid & the line tested by EPC Contractor.
Backfill around the service pipes shall be carried out using the appropriate material.
and compacted to the project specification requirement with the test results provided
confirming the conformance
The existing services shall be reinstated accordingly.
General fill up to the underside of road formation shall be carried out in 150mm compacted
layers using mechanical methods to the specification conformance.
The finishing shall be carried out using approved asphalt mix.
Second Instance
In the second instance the work shall be carried out on part 2 diverting the traffic to the road
portion on the completed part 1.The second instance shall commence only when the first is
completed allowing the traffic to ply.
All the aforesaid operations shall be repeated for the 2 nd instance allowing the traffic on the
completed Instance 1
The traffic management system shall be removed after the road crossing is cleared of all
debris or obstructions.
Either side of the road X-ing shall be provided with relevant markers to indicate the services
Major Equipment
Excavator.Dump trucks.Compactors.
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              190 of



Jack Hammer, Compressor, hydro jetting (depending on necessity)
Attachment
Sketch showing the traffic management scheme

#76



Road crossing for laying
84”GRE pair seawater
Cooling lines
At
Avenue „d‟ / corniche
Junction
 Top

Index
Scope
Reference documents
Definitions
Responsibilities
Safety
Method including traffic management scheme
Equipment
Attachment
Scope
The statement is aimed to propose the procedures to be adopted to carry out the excavation at
the road to facilitate to lay the pipe lines 1 # PAIR 84” GRE SEA WATER COOLING SUPPLY
LINES at Avenue‟D‟ and „Corniche Road‟ junction identified on the attached drawing to the
following references
Reference documents
Specification Excavation & Backfilling for Underground structures.
Drawing No.
Piping Interconnection Drawings- SeaWater Cooling Supply Lines
Definitions
PSM           Project Site Manager
CSM           Construction Manager
CS            Construction Superintendent
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              191 of



SE                       Site Engineer
FM                       Foreman
QC                       Quality Control
Responsibilities
PSM shall control the overall operations
CM shall arrange the resources required accordingly and be overall responsible for the
excavation operation
CS shall control, monitor and direct the SE, FM and workforce for the operations
SE shall be responsible for all the site operations and follow the instructions of the CS
Any mishap on the excavation operation shall immediately be notified to the CS and the CM for
the immediate action if so required for any possible remedy or record or the authority review
whatsoever,the case may be
FM shall execute the operations deploying the workforce. FM shall explain in full in the
language the work persons understand about all the instruction and the ToolBox talks every
day and check that the same are followed up regularly
QC shall inspect all the operations according to the specifications
EPC Contractor shall conduct surveillance
Safety
Prior to the commencement of any activity the labour force shall receive a Toolbox talk
relevant to the operation concerned on the project site safety requirements. Any process is
adopted having a particular safety risk shall be assessed and addressed as required to raise to
a minimum standard / an acceptable mark.
In the present case the excavation has to be carried out on the Operating Authority area,
therefore all the regulated precautions shall be resorted to effect a full safety standard.
ToolBox Talks
While conducting ToolBox Talks, a representative from the authority shall be involved to
witness and sign the instruction imparted with the workers prior to the commencement of the
operations to make a record.
Only English literate Foreman shall be employed to work on the excavation execution.
Excavation Work Permit- A copy of the work permit shall be posted on a mini board installed
on site to be noticeable to all the relevant persons involved on the crossing
Traffic Management-Sign boards keep up-All the personnel shall be briefed about the safe
keep up of the boards
Barricades,cones, markers and the night-lights, flood lights etc. shall be arranged as required
for a complete safety. No oil spillage shall be allowed.
The sides of the excavation shall be sloped with the barriers placed to indicate the excavation
work in progress
Flagman-On all the direction, in addition to the traffic sign boards, a flagman shall be engaged
to operate full time to direct the traffic about the excavation work in progress by waving the flag
for all the vehicles passing by
Hand Excavation- Excavation required to be by hand shall only be carried out manually. In
case certain services not shown on the record drawings such as fibre optics cable is

Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              192 of



discovered, the excavation shall be ceased to be continued until the decision to hydrojetting
is taken up and the authority are involved.
Jack Hammer- The worker engaged on operating this equipment shall use protective glass
and work in phases with pause intervals. The compressor air pressure shall be monitored from
time to time so that the hammer works smoothly. The compressor shall be place within the
barricade limits
Access to trench- The workers shall clearly be instructed to use only the ladders to enter in or
come out. No jumping shall be allowed
Machine Excavation
The operators shall be explicitly explained and instructed about the requirement of the reverse
signal and sound when operating reverse. The truck driver shall also be instructed similarly.
Banksman shall be engaged while the equipment operate.
No violation of the traffic rules shall be allowed
Deep Trenches
Since the proposed excavation is wide and deep all the safety measures shall be resorted to
and If required, the shoring shall be provided to prevent the caving in. The trench depth being
more than 1200 mm.adequate means of exit such as Aluminium ladder or steps shall be
provided and located no more than 8 m of lateral travel.
Existing Services
2 # electric poles and the other various categories of about 8 to 10 # running services ducts
and the cables etc shall be properly diverted according to the regulatory requirement and
preserved until reinstated
Safety Supervision
A competent inspector shall inspect the trench daily to assess the safety measures adopted.
Method
The required permit to work shall be obtained from the Plant Refinery Division.
The record drawings regarding the existing services shall be obtained.
A traffic management scheme has been presented herein and shall be produced on site as
detailed on the attached sketch for this road crossing which includes, reduced speed sign,
temporary diverted roads sign, men at work sign, warning signs, informatory signs, safety
barriers, night lighting and road cleaning activities etc.
The traffic management scheme shall be reviewed and approved by EPC Contractor prior to
commencing the work.
The aforesaid traffic management scheme shall be implemented as described below:
TRAFFIC MANAGEMENT SCHEME ROAD CROSSING –
Corniche Road / Avenue „D Junction‟
Drawing reference
This proposed crossing is located on the Road Avenue „D‟ between the following
Co-ordinates as shown on the referred drawing.
Avenue „D‟ is a 2-way road carrying single lane on either way
Corniche Road is a 2-way road with a central verge, carrying 2 lanes on either way on the
West direction and without a central verge but single lane on the Eastern direction.
2 # serving electric pole are located 1 at the curve and the other in the Northern central verge
which shall be effected by the proposed excavation because of encroachment on the verge.
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              193 of



The central verge partly, the island partly, guard rail fully about 30 m with channels, Corniche
street sign board, Kerb stones shall all be effected by the construction of the proposed road
crossing
The road shall be divided in 2 parts as shown on the sketch as L1 and L 2 on either side of the
carriageway.
In the first instance the work shall be carried out on part L1 diverting the traffic to the road
portion on the part L2 as shown on the sketch.
In the second instance the work shall be carried out on part L2 diverting the traffic to the road
portion on the completed road portion on the part L1 as shown on the sketch.
The second instant shall be commenced only when the first has been completed and the traffic
can ply.
The directory signboards shall also be placed on the 1 st street road East West on both ways to
indicate the work at the crossing
For the traffic on both roads at‟ 3‟ locations bothways, the first reduce speed for traffic
diversion informatory board depicting shall be located at 300 m from the point of the proposed
crossing, the second depicting diversion signs be located at 200 m and the third depicting men
at work sign be located at 100 m on either way in the opposite directions.
A Flagman shall be engaged full time on both the directions to guide the traffic about the
ongoing excavation operations in addition to the conventional signboards
The following activities are involved to produce the Traffic Diversion
Management Scheme
To excavate by hand and expose all the underground facilities
Various types of electrical, telecom and other services are running below and near the
proposed crossing
Trial pits to be excavated in size 5mx2mx1.5m deep by hand tools
To seam the area with the detectors to ascertain the access to the cable
To expose the cable fully and to be inspected by the authorities / Operating Authority
After the exposure, all the cables to be covered with split PVC pipe to continue the excavation
mechanically according to the authority directions and as agreed
To excavate the remaining portion by the excavator machine
To have authority inspection
The pipes to be laid by others
To fill the bedding material according to the specification requirement
To reinstate the diverted services
To reinstate the central verge to the existing state
To reinstate the CORNICHE ROAD board and the metallic rail guard
Details
The Traffic Management Scheme shall be executed as explained in the foregoing and to the
traffic manual directions.
The first section of the proposed road crossing as per the attached sketch shall be marked by
the surveyor on the actual location. All the existing services shall be identified from the Record
drawings as well as by digging and measures to protect or divert temporarily resorted to
according to the regulations.
The asphalt shall be cut using jackhammers
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              194 of



The road section shall be excavated to the existing cables manually for which the trial pit may
be made prior to the full manual excavation is proceeded and after ascertaining the safe
procedures the exposures be completed.
After the exposure of the cables, the Operating Authority authorities shall inspect and the
cables be diverted accordingly following which the remaining machine excavation be carried
out to the specified levels
The excavated material shall be removed from the site to stockpile area.
Appropriate bedding material shall be placed within the excavated trench to the correct service
level. Where required, this bedding shall be compacted and tested.
The excavated trench shall be inspected by the authorities as required.
The GRE pipes shall be laid by others.
Backfill around the service pipes shall be carried using the appropriate material.
The service pipes surrounding material shall be compacted as per the project specification
requirements. Test results shall be provided for the specification conformance verification.
The existing services shall be reinstated accordingly.
General fill up to the underside of road formation shall be placed in 150mm compacted layers
using mechanical methods to the specification requirements.
A concrete slab shall be cast up to the bottom of the finished asphalt level.
The finishing shall be carried out using approved asphalt mix.
The traffic management system shall be removed after the road crossing has been cleaned of
any debris or obstructions.
Either side of the road X-ing shall be provided with markers to indicate the services
Major Equipment
Excavator.Dump trucks.Compactors.
Jack Hammer, Compressor, hydro jetting (depending on necessity)
Attachment
Sketch showing the traffic management scheme
Drawings including the traffic diversion
#77

Tennis courts surfacing
Top

Index
Scope
Reference documents
Definitions
Responsibilities
Safety
Method
Equipment
Attachment

Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              195 of




Scope
The statement is aimed to propose the procedures to be adopted to carry out the Surfacing on
2 #s Tennis Courts located in the Camp
Reference documents
Drawing No.
Definitions
PSM                      Project Site Manager
CSM                      Construction Manager
CS                       Construction Superintendent
SE                       Site Engineer
FM                       Foreman
QC                       Quality Control
Responsibilities
PSM shall control the overall operations
CM shall arrange the resources required accordingly
CS shall control, monitor and direct the SE, FM and workforce for the operations
SE shall be responsible for all the site operations and follow the instructions of the CS
FM shall execute the operations deploying the workforce. FM shall explain in full in the
language the work persons understand about all the instruction and the ToolBox talks every
day and check that the same are followed up regularly
QC shall inspect all the operations according to the specifications
EPC Contractor shall conduct surveillance
Safety
Prior to the commencement of any activity the labour force shall receive a Toolbox talk
relevant to the operation concerned on the project site safety requirements. Any process
adopted having a particular safety risk shall be assessed and addressed as required to raise to
a minimum standard / an acceptable mark.
The workers shall take all the precautions to avoid the skin and the eye contacts by using the
safety glasses, hand gloves, the uniform, gun shoes all according to the manufacturer‟s
instructions. Immediate medical attention shall be provide when required
Safety Supervision
A competent inspector shall visit the area daily to assess the safety measures adopted. Any
snag observed during the inspection shall be notified to the supervisor present who
immediately act to bring the safety measures to an acceptable standard
Storage
The bags shall be stored in a cool shaded area prior to use




Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              196 of




Material
MBT proprietary material
Concresive 1414
MasterTop 512
Concresive 1414 is a 2 parts epoxy bonding agent
Mastertop 512 is a ready to use non-metallic and non oxidising synthetic mineral aggregate
and cementitious product applied as a topping onto the existing new concrete slab as a hard
durable wearing course. 10 to 12 mm thick. Total surface area of the Tennis Courts 2 # 930
m2
Method
The following operations are involved to carry out the surfacing
Substrata preparation
Priming and Bonding
Mixing and Application
Curing
Details
The area shall be closed to all persons except the workers and other personnel
The surface of concrete shall be cleaned of all contamination such as oil, grease or fat which
be removed before the preparations are commenced with
High pressure water jetting shall be used to prepare the concrete surface to a coarse texture
ensuring all weak or friable concrete be removed along with the contaminants
The concrete is already more than 28 days
Oil free Compressed air shall be used to remove dust making the surface clean & dry
The surface shall be primed with Concresive 1414 ensuring total coverage of the surface
A forced action Mixall mixer shall be used to mix Mastertop 512 according to the
manufacturer‟s instructions
The content of the bag shall be poured into the mixer followed by blending for about 30
seconds, thereafter slowly adding 2.3 to 2.4 litres of water per 25 kg bag allowing to mix for 3
minutes
In hot weather chilled clean water shall be used for mixing
The primed surface shall be prepared to be guided for the proposed profile formation by using
timber / wooden straightedge battens 10 mm thick
The mixed mortar shall have a plastic consistency exhibiting low slump which be evenly
spread over the primed surface already prepared as expressed in the foregoing
A straightedge shall be used to systematically tampen and level the Mastertop 512.
The floating material shall be pressed firmly on the primed surface using a wooden float to
produce the material evenly spread and compacted
A steel trowel shall be used to carry out the finishing.
Curing
The curing shall be carried out immediately after the final trowelling operation has been
completed by either covering with polythene sheets or by the application of Masterkure 181
applied at a rate of 1 litre per 5 m2

Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              197 of



All the surfaces shall be protected from traffic until hardened( for light traffic the limit is 24
hours and for heavy 72 to 96 hours )
Major Equipment
Compressor, Mixer, Air Blower
Jack Hammer, Compressor, hydro jetting (depending on necessity)
Attachment
MBT Method Statement
#78
Precasting lighting poles foundations
Top

Index
Scope
Reference documents
Definitions
Responsibilities
Safety
Method
Equipment
Attachment
Scope
The statement is aimed to propose the procedures to be adopted to carry out the pre casting,
transporting and installing on exact site locations the street lighting poles foundation bases 319
#
Reference documents
Drawing No.
Specification
Definitions
PSM                      Project Site Manager
CSM                      Construction Manager
CS                       Construction Superintendent
SE                       Site Engineer
FM                       Foreman
QC                       Quality Control
Responsibilities
PSM shall control the overall operations
CM shall arrange the resources required accordingly
CS shall control, monitor and direct the SE, FM and workforce for the operations
SE shall be responsible for all the site operations and follow the instructions of the CS
FM shall execute the operations deploying the workforce. FM shall explain in full in the
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              198 of



language the work persons understand about all the instruction and the ToolBox talks every
day and check that the same are followed up regularly
QC shall inspect all the operations according to the specifications
EPC Contractor shall conduct surveillance
Safety
Prior to the commencement of any activity the labour force shall receive a Toolbox talk
relevant to the operation concerned on the project site safety requirements. Any process
adopted involving a particular safety risk shall be assessed and addressed as required to raise
to a minimum standard / an acceptable mark.
All the safety precautions required to be adhered to while working on the excavations, blinding,
forms, rebars, concrete pouring, waterproofing etc.all according to the acceptable standards
shall be adopted on the operations concerned
Adequate safety shall be observed during lifting and offloading the precast foundations to the
relevant locations to avoid any mishap BY OBSERVING THE REGULATORY CRANE
FITNESS REQUIREMENT AND VALIDITY OF PERMIT. Only competent personnel shall be
engaged to carry out the operation
The crane and the trailer operators shall adhere to all the traffic rules while carrying out the
operations and if so required, a banksman be engaged to direct the movement
The crane shall not be operated during the inclement weather conditions with dust storms
Immediate medical attention shall be provide as and when required
Safety Supervision
A competent inspector shall visit the area daily to assess the safety measures adopted. Any
snag observed during the inspection shall be notified to the supervisor present who
immediately act to bring the safety measures to an acceptable standard
Material
Concrete, Rebars / Lifting Lugs, Anchor Bolts,
100 mm dia 350 internal radius PVC Cable Duct etc.
Method
Pre casting Area-The existing yard being used for the pre casting of manholes, catch basins
etc. shall be employed for this purpose also
The following operations are involved to carry out the production of the light poles foundation
bases
Pre installation operations
To fabricate and erect the side forms 4 #s to the specified dimensions
To fabricate the rebars according to the specified details
To provide the non critical cathodic protection
To provide the PVC cable duct
To provide the bolt assesmbly to the requirement and location
To provide the lifting lugs to carry a gravity load of at least 3 tonnes + handling stresses
To pour the concrete
To cure the concrete immediately after pouring


Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              199 of



Post casting operations
To cure for the specified period
To excavate the location to the required formation level
To blind the area to be founded with concrete
To waterproof the blinding as specified
To keep the area ready in all respects well oriented & aligned to receive the foundation directly
to be offloaded
To apply the water proofing membrane around as specified
To provide the protection board as specified
To back fill the surrounding space to the relevant grade level
Details
The typical size of the foundation is 1000x1000mm in plan and 1100mm deep
According to the drawing 319 # are specified to be constructed for a quantity 351 m3
A possible of 10 units shall be produced by pre casting every day on an average
The forms to the exact size with the preformed chamfers shall be prepared and erected
The steel rebars shall be cut, bent to the required shape, placed and the cage prepared
holding 75mm concrete spacers, be positioned into the forms.
1 # 350 mm internal radius 100 mm dia PVC cable duct formed to the dimensions shall be
anchored by binding wires to the exact locations shown on the drawing keeping the upper end
flush with the concrete top
The Lifting lugs as shown on the sketch shall be fixed in to the correct locations
The forms for the block outs for the lifting lugs shall be fixed in to the correct locations as
shown without clashing with the duct or the rebars allowing a protrusion of the hook
The bolt assembly shall be fixed in exact position according to the design details
The non-critical cathodic protection shall be arranged using a metallic continuous binding wire
connecting all the horizontal rebars terminating into a boss fixed at one location near the top in
the middle of the side opposite the duct carrying portion
All the supports and the dimensions shall be checked and the plumb monitored
Civil Contractor QC inspection shall be conducted followed by the EPC Contractor inspection
The concrete shall be poured to all the prepared units in 3 layers in vertical sequence
The appropriate vibrator shall be used for the compaction of the concrete
During concreting, care shall be taken to keep the anchor bolts‟ position undisturbed and the
intermittent checks be continuously made to monitor the spacing / centres between the bolts
After the concrete is poured in full & well compacted, the surface shall be levelled using a
wooden float followed by light steel trowel
Immediately after the concrete starts setting, approved curing compound shall be sprayed on
the surface forming a continuous membrane which be covered over with a polythene sheet
according to the specifications
After 2 hours, the polythene sheet shall be temporarily removed to spread over the concrete
surface the saturated burlap cloth or hessian, and recovered immediately
The side forms shall be removed within the specified period
The vertical concrete surfaces shall be spread with the curing compound immediately after
striking the forms and covered with the polythene sheet according to requirement
The curing shall be continued for the specified period
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              200 of



The relevant locations shall be made ready to receive the precast units by completing the
excavation, blinding, the horizontal waterproofing and forming the correct alignment
Civil Contractor QC inspection shall be conducted for the‟location to receive followed by EPC
Contractor approval
The unit shall be lifted by a mobile crane, loaded gently onto a trailer and transported to the
location for offloading on to the prepared „location to receive‟ the unit
The unit shall be installed on the marked location according to the correct orientation to the
lighting layout drawing
Civil Contractor QC inspection shall be conducted followed by EPC Contractor approval
The protruding lifting lug eyes shall be cut to 60 mm inside the block out, the void filled with
concrete by first scabbling the internal surface followed by cement slurry grouting and pouring
concrete
The external surfaces of the foundation shall be applied with the concrete protective
membrane according to the specifications
Civil Contractor QC inspection shall be conducted followed by the EPC Contractor approval
The membrane protection board shall be provided covering the surface to the specified details
The back filling shall be carried out according to the specification upto the required levels in
layers and upto the required ground grade or the pavement
The points to locate the cathodic protection shall be provided with a marker to trace the boss
The sequence shall be repeated for all the lighting poles foundations
Major Equipment
Compressor, Mobile Crane, Trailer
Concrete Pump, Transit mixer
Attachment
Lifting arrangement sketch
#79

Lighting poles foundations
Top

Index
Scope
Reference documents
Safety
Method
Equipment
Attachment
Scope
The statement is aimed to propose the procedures to be adopted to carry out the
pre casting, transporting and installing on exact site locations the street lighting poles
foundation bases 319 #

Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              201 of



Reference documents
Drawing No.
Specification
Safety
Prior to commencement of any activity, the labour force shall receive a STARRT Card /
Toolbox talk relevant to the operation concerned on the project site safety requirements.
Necessary measures shall be applied to any process involving a safety risk
All safety precautions necessary during working on excavations, blinding, forms, rebars,
concrete pouring, concrete protection etc. shall be applied to acceptable standards
Adequate safety measures shall be adhered to during lifting and offloading precast foundations
to relevant locations avoiding any mishap BY OBSERVING THE REGULATORY CRANE
FITNESS REQUIREMENT AND VALIDITY OF PERMIT.
Only competent personnel shall be engaged to carry out the operation
Crane and trailer operators shall abide by all traffic rules while carrying out operations and if so
required, a banksman shall be engaged to direct the movement
The crane shall not be operated during the inclement weather conditions with dust storms
Safety Supervision
A competent inspector shall visit the area daily to assess the safety measures adopted. Any
snag observed during his visit shall be notified to the supervisor present who immediately act
to bring the safety measures to an acceptable standard
Material
Concrete, Rebars / Lifting Lugs, Anchor Bolts,
100 mm dia 350 internal radius PVC Cable Duct, Bitustick XL, Masterseal 300H
Method
Pre casting Area- the existing yard being used to pre cast manholes, catch basins etc. shall be
employed for this purpose also
The following operations are involved to carry out the production of the lighting poles
foundation bases
Pre installation operations
The typical size of the foundation is 1000x1000mm in plan and 1100mm deep
According to drawing 319 # are specified to be constructed (quantity 351 m3)
On an average 10 units shall be produced by pre casting every day
The forms to the exact size with the preformed chamfers shall be prepared and erected
The steel rebars shall be cut, bent to the required shape, placed and the cage prepared
holding 75mm concrete spacers, and positioned into the forms.
1 # 350 mm internal radius 100 mm dia PVC cable duct formed to the dimensions shall be
anchored by binding wires to the exact locations shown on the drawing keeping the upper end
flush with the concrete top
The Lifting lugs as shown on the sketch shall be fixed in at the correct locations
The forms for the block outs for the lifting lugs shall be fixed in at the correct locations as
shown without clashing with the duct or rebars allowing a protrusion of the hook
Bolt assembly shall be fixed in at exact position according to the design details

Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              202 of



Non-critical cathodic protection shall be arranged using a metallic continuous binding wire
connecting all the horizontal rebars terminating into a boss fixed at one location near the top in
the middle of the side opposite the duct carrying portion
All the supports and dimensions shall be checked, corrected if required and the plumb
monitored
An Civil Contractor QC inspection shall be conducted at regular intervals throughout the
operations
The concrete shall be poured to all the prepared units in 3 layers in vertical sequence
The appropriate vibrator shall be used for the compaction of the concrete
During concreting, care shall be taken to keep the anchor bolts‟ position undisturbed and the
intermittent checks be continuously made to monitor the spacing / centres between the bolts
An Civil Contractor QC inspection shall be conducted prior to concrete pour & ITP signed off
After the concrete is poured in full & well compacted, the surface shall be levelled using a
wooden float followed by light steel trowel
Curing
Immediately after the concrete is finished, the surface shall be covered with polythene sheet
with the edge lapped or tied down to exclude air circulation without permitting the membrane to
be in touch with concrete surface according to the specifications
After the concrete has stiffened but no longer than 2 hours, the polythene sheet shall be
removed followed by immediate covering the surface with saturated( soaked with mix quality
water) hessian and recovered with polythene sheet to prevent evaporation from the hessian.
Throughout the curing period, the hessian shall be maintained in a permanent wet condition
using mix quality water
The side forms shall be removed after the specified period of 24 to 36 hours as agreed
The vertical concrete surfaces shall be draped with the saturated hessian immediately after
striking the forms and covered with the polythene sheet held firmly in place along all edges &
kept continuously wet for duration of curing
The curing shall be continued for the specified period
An Civil Contractor QC inspection shall be conducted from time to time throughout the
operations
Installation operations
The relevant locations shall be made ready to receive the precast units by completing the
excavation, blinding, the concrete protection and forming the correct alignment
AN Civil Contractor QC inspection shall be conducted for the'location to receive' & ITP signed
off
The unit shall be lifted by a mobile crane, loaded gently onto a trailer and transported to the
relevant area to offload on to the prepared „location to receive‟
The unit shall be installed on the marked location according to the correct orientation to the
lighting layout drawing
AN Civil Contractor QC inspection shall be conducted
The protruding lifting lug eyes shall be cut to 60 mm inside the block out, the void filled with
concrete by first scabbling the internal surface followed by cement slurry grouting and pouring
concrete

Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              203 of



The below ground surfaces of the foundation shall be applied with concrete protective
membrane according to the specifications
AN Civil Contractor QC inspection shall be conducted
The membrane protection board shall be provided covering the surface to the specified details.
The backfilling shall be carried out in layers according to the specification upto the required
levels The points to locate the cathodic protection shall be provided with a marker to trace the
boss. Top surface of the foundation shall be applied with above ground concrete protection as
specified
EPC Contractor surveillance / inspection / approval shall be according to the approved
ITPs
Major Equipment
Compressor, Mobile Crane, Trailer
Concrete Pump, Transit mixer
Attachment
Lifting arrangement sketch
#80

Sea water surge basin
Concrete protection master seal 550
Top

Index
Scope
Reference documents
Definitions
Responsibilities
Safety
Material
Method
Equipment
Attachment
Scope
This statement is aimed to present the proposed procedures to be adopted to apply the
specialist protection coating material on the internal concrete surfaces (shown on the drawings
by cross hatching) of the sea water surge Basin according to the specifications.
References
Drawings
Specifications
Master seal 550-product data sheet

Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              204 of



-Protection to concrete Surfaces
Definitions
PSM          Project Site Manager
CSM          Construction Manager
CS           Construction Superintendent
SE           Site Engineer
FM           Foreman
QC           Quality Control
Responsibilities
PSM shall control the overall operations
CM shall arrange the resources required accordingly
CS shall control, monitor and direct the SE, FM and workforce for the operations
SE shall be responsible for all the site operations and follow the instructions of the CS
FM shall execute the operations deploying the workforce. FM shall explain in full in the
language the work persons understand about all the instruction and the toolbox talks every day
and check that the same are followed up regularly
QC shall inspect all the operations according to the specifications
EPC Contractor shall conduct surveillance
Safety
Prior to the commencement of work, the labour force shall receive a tool box talk on the
Project Site Safety requirements. Any process adopted which may involve a particular Safety
risk, shall be assessed to the requirement for Site conditions and be taken care of.
Scaffolding shall be erected to afford access to the working personnel according to the project
requirements. Hand rails ladders and the toe boards shall be fitted and inspected prior to use.
During mixing and application of master seal 550, personnel protective equipment shall be
used i.e. overalls, goggles, gloves (to avoid material contact to eyes, mouth and skin)
Material storage / disposal of used containers / waste material
Materials shall be stored out of direct sunlight clear of ground and protected from rainfall.
Used containers shall be collected and disposed off according to the state regulations.
Medical attention shall immediately be made available as and when required
Materials
Coating, Masterseal 550
Master seal 550 is a two component acrylic modified cementitious coating that requires only
site mixing to form an ideal product to waterproof, resurface concrete, masonry and most other
construction materials. Simply applied by stiff brush, roller or trowel it forms a waterproof and
flexible coating providing an effective barrier to waterborne salts and atmospheric gases.
Method
The method involves the following sequences in general.
Surface preparation
Mixing
Application
To keep up the exact coverage to form 1 mm thick coating an area of 11 m2 shall be marked
on the concrete surface. The contents of the bag shall be applied on this area only
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              205 of



At Joints
The material coating shall terminate at the joints (Refer to the attached sketch) which are to be
treated with sealant.
The part of the coating that has to be embedded into the joint sealant shall be applied first
followed by the major area on the panel be coated thereafter
Details
All grease, oil, dust, residual curing compound, mould release agent or other contaminants
which could impair adhesion shall be removed from the surface by degreasing and washing.
Arrises shall be rounded off and the surface protrusions ground down to ensure smooth
substrata
The whole surface to be coated shall be cleaned using water jetting from a distance of 2 to 3 m
from the panel surface and visually inspected to ensure that the required degree of roughness
has been achieved which be evident at a stage when the aggregate be exposed on the
surface.
All the holes, voids, depressions, spalls etc. shall be filled with Masterseal 550 mixed to a
trowel consistency, scraped lightly into the surface, allowed to dry and later roughened by
hand wire brush on the small areas and gently water jetted on the larger areas.
The filled areas shall be visually inspected to ensure that the correct mechanical key is formed.
Mixing
Master seal supplied in the pre-measured units shall be mixed on site using clean containers.
The powder shall be slowly added to the liquid component and agitated / mixed for 2 minutes
using a slow speed hand power drill fitted with a suitable paddle attachment until a
homogeneous lump free consistency is obtained.
The mix quantity shall be such that it could be consumed in one hour during application without
allowing any retempering with water.
Application
Coverage 1.8 Kg / sqm at 1 mm thickness
The material shall be 1 mm thick applied in one coat
In hot weather the surface to be coated shall be shaded from direct sunlight.
The prepared surface area to be coated shall be saturated with fresh and clean water
 Civil Contractor QC inspection shall be conducted followed by EPC Contractor approval
The material shall in no case be applied on the dry surface
The mixed material shall be applied while the surface is visibly damp without standing water
using short stiff brush or roller with short hair.
(Roller shall be used in major / large areas)
The evenness and the thickness of the applied coating shall be regularly ascertained by the
consumed quantity to the applicable ratio of 11 m2 each container during application while the
material is still wet.
The coverage of 11-m2 surface shall be the evidence for the actual formation of 1-mm thick
coating.
The material shall be allowed to dry and visually inspected
Civil Contractor QC inspection shall be conducted followed by EPC Contractor approval
Any missed areas shall be saturated and then touched up.
No curing shall be carried out
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              206 of




Equipment
Water tanker with water jetting arrangement
Hard brushes for minor areas
Clean container
Slow speed drill with paddle attachment
Stiff brush / Roller
Attachment
Masterseal 550 Data sheet and statement
Typical sketch for joint for guidance purpose
#81

Concrete coating                                                                       of                structures                                          using
masterseal 550
Top
Index
Scope
Reference documents
Safety
Material
Method
Equipment
Attachment
Scope
This statement is aimed to propose the procedures to be adopted to apply the specialist
protection coating material on those concrete surfaces requiring special protection e.g. The
interior of Sea water Surge basin & Collection Sumps
References
Specifications
Master seal 550-product data sheet
Protection to concrete Surfaces
Safety
Prior to the commencement of work, the labour force shall receive a STARRT card / Tool box
talk relevant to the operation concerned on the Project Site Safety requirements.
Necessary measures shall be applied to address any risk involved on any process
Tagged scaffolding shall be erected to afford access to the working personnel
Personnel working on sand blasting & mixing and application of master seal 550, shall wear
overalls, gloves, safety glasses and masks
Used containers shall be collected and disposed off according to the state regulations.


Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              207 of




Method
Joints - The material coating shall terminate at the joints to be treated with sealant. As shown
on the attached sketch
The part of the coating to be embedded into the joint shall be applied first to permit sealant
application followed by the major area on the panel to be coated thereafter
Surface preparation
Arrises shall be rounded off and protrusions ground down to ensure smooth substrata
The whole surface to be coated shall be lightly sand blasted & visually inspected to ensure that
the required degree of roughness has been achieved.
All holes, voids, depressions, spalls etc. shall be filled with Masterseal 550 mixed to a trowel
consistency, scraped lightly into the surface, allowed to dry and later roughened by hand wire
brush on small areas and lightly sand blasted on larger areas.
The filled areas shall be visually inspected to ensure that the correct mechanical key is formed.
Mixing
Master seal supplied in the pre-measured units shall be mixed on site using clean containers.
The powder shall be slowly added to the liquid component and agitated / mixed for 2 minutes
using a slow speed hand power drill fitted with a suitable paddle attachment until a
homogeneous lump free consistency is obtained.
The mix quantity shall be consumed in one hour during application without allowing any
retempering with water.
Application
Coverage 1.8 Kg / sqm at 1 mm thickness
One coat application shall be 1 mm thick
In hot weather the surface to be coated shall be shaded from direct sunlight.
An area of 11 m2 shall be marked on Concrete surface to consume 1 bag content to produce 1
mm thick coating.
Prepared surface area to be coated shall be saturated with fresh and clean water
Civil Contractor QC inspection shall be conducted
Material shall in no case be applied on the dry surface
Mixed material shall be applied on the visibly damp surface without standing water using short
stiff brush or roller with short hair. (Roller shall be used in major / large areas)
Evenness and the thickness of the applied coating shall be regularly monitored relating the
consumed quantity @ 11 sqm / bag during application while the material is still wet.
Applied material shall be allowed to dry and visually inspected
Civil Contractor QC inspection shall be conducted and the ITP signed off
Any missed areas shall be saturated and then touched up.
No curing shall be carried out
Field samples shall be taken to confirm 1mm thick coating has been applied
Equipment
Sand blasting package
Compressors
Clean container
Slow speed drill with paddle attachment
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              208 of



Hard brushes for minor areas
Stiff brush / Roller
Attachment
Masterseal 550 Data sheet and statement
Typical sketch for joint (for guidance)
#82

Above ground concrete protection
Seawater surge basin
Top

Index
Scope
Reference documents
Definitions
Responsibilities
Safety
Storage
Material
Method
Equipment
Attachment
Scope
This statement is aimed to propose the procedures to be adopted to form a protection coating
on the above ground RCC walls‟ external faces as well as on the internal surface areas other
than those where Masterseal 550 shall be applied
References
Drawing
Specifications
Master seal 300 H-product data sheet
Master seal 181 S-product data sheet
Protection to concrete Surfaces
MAR for Masterseal300 H
MAR for Masterkure 181
Definitions
PSM           Project Site Manager
CSM           Construction Manager
CS            Construction Superintendent
SE            Site Engineer
FM            Foreman
QC            Quality Control
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              209 of




Responsibilities
PSM shall control the overall operations
CM shall arrange the resources required accordingly
CS shall control, monitor and direct the SE, FM and workforce for the operations
SE shall be responsible for all the site operations and follow the instructions of the CS
FM shall execute the operations deploying the workforce. FM shall explain in full in the
language the work persons understand about all the instruction and the toolbox talks every day
and check that the same are followed up regularly
QC shall inspect all the operations according to the specifications
EPC Contractor shall conduct surveillance
Safety
Prior to the commencement of work, the labour force shall receive a tool box talk on the
Project Site Safety requirements. Any process adopted which may involve a particular Safety
risk, shall be assessed to the requirement for Site conditions and be taken care of.
Scaffolding with the hand rails, the ladders and the toe boards fitted and inspected prior to use
shall be erected to provide access to the working personnel according to the project
requirements.
Only tagged scaffolding comprising all the guard rails foot rails etc. shall be used for the work
at heights according to safety requirements.
The personnel shall use protective clothing, gloves eye protection glasses, masks etc., for to
avoid skin contact.
Plenty of clean water shall be available all the time.
Medical attention shall be available all time to treat the adverse effects.
Transportation shall be available to move the effected personnel to the hospital should the
circumstances so require.
Material storage / disposal of used containers / waste material
The material shall be stored under cover out of direct sunlight clear of ground, protected from
rainfall as well as temperature extremes.
Product shelf life is 12 months subject to proper storage
Care shall be taken during use and storage to avoid contact with eyes, mouth, skin and
foodstuffs.
The containers shall be resealed after use.
Immediate medical attention shall be called for in case of any adverse effect to the personnel
handling the product
Damaged tins shall be disposed off according to the state regulations.
Material
Master Builder Technology Product
Masterseal 300H - an acrylic based, elastomeric decorative, flexible, anti-carbonation and
waterproof protective coating designed for the protection of concrete structures against
carbonation and chloride ingress.
Masterseal 181S- primer system


Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
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Masterseal 300 H filler
Method
This application involves the following sequences
Cleaning and making up the surface
Priming the surface
Coating the surface
Details
Preparation
All surfaces shall be free from oil; grease, friable matters and curing compound.
The surfaces shall be cleaned from dust / sand using compressed air.
Arrises shall be rounded off and the protrusions ground so that the resulting surfaces appear
smooth.
The surfaces shall be brush primed with Masterkure 181S and subsequently Masterseal 300H
mixed with Masterseal 300 H filler applied as a scrape coat over blowholes and depressions.
The primed surface shall be allowed to dry tack free for a minimum duration of 2 hours before
applying Masterseal 300H coating.
Application
Masterseal 300 H shall be applied directly from the containers using a brush or roller @ 0.8
litre per sqm surface coverage to achieve a continuous coating
The continuous coating may be achieved in 1 or 2 coats of application
The coating shall be protected from the rain and humidity for 24 hours / until it dries out
using polythene sheets keeping off the area.
The coating shall be applied when the humidity is less than 90 %
The coating shall not be applied in the dusty weather conditions
No post application curing is required
The areas to be coated shall be protected from direct sunlight by net shading in the hot
weather conditions and the ambient temperature be more than 5 degree Celsius.
Equipment
Brush
Roller
Attachment
MBT datasheet & Statement
#83


Sea water surge basin
joint seal

Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              211 of




  Top

Index
Scope
Reference documents
Definitions
Responsibilities
Safety
Method
Equipment
Attachment
Scope
This statement is aimed to present the proposed procedures that shall be adopted to apply the
sealant to fill the joints formed in the walls and the base. This statement shall be construed in
conjunction with Method Statement # approved / IFC vide Transmittal site-including an
alternative to this document. Any of the 2 methods may be used for the joint treatment
according to the convenience on site
References
Specifications
Definitions
PSM           Project Site Manager
CSM           Construction Manager
CS            Construction Superintendent
SE            Site Engineer
FM            Foreman
QC            Quality Control
Responsibilities
PSM shall control the overall operations
CM shall arrange the resources required accordingly
CS shall control, monitor and direct the SE, FM and workforce for the operations
SE shall be responsible for all the site operations and follow the instructions of the CS
FM shall execute the operations deploying the workforce. FM shall explain in full in the
language the work persons understand about all the instruction and the toolbox talks every day
and check that the same are followed up regularly
QC shall inspect all the operations according to the specifications
EPC Contractor shall conduct surveillance
Safety
Prior to the commencement of work, the labour force shall receive a tool box talk on the
Project Site Safety requirements. Any process adopted which may involve a particular Safety
risk shall be assessed to the requirement for Site conditions and be taken care of.


Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              212 of



Scaffolding with the hand rails, the ladders, the toe boards fitted and inspected prior to use
shall be erected to provide access to the working personnel according to the project
requirements.
Only tagged scaffolding comprising all the guard rails foot rails etc. shall be used for the work
at heights according to safety requirements.
Material storage / disposal of used containers / waste material
Materials shall be stored out of direct sunlight clear of ground and protected from rainfall.
Used containers shall be collected and disposed off as per project requirements.

Medical attention shall immediately be made available as and when required
The personnel shall use the PPE, gloves, masks, eyeglasses etc, and to avoid skin contact.
use of barrier cream shall also be made.
Hands shall be cleaned by Industrial cleaner followed by washing with soap and water.
Material safety data shall be referred to for disposal and any further information.
A safety inspector shall visit the site every day and instruct the supervisor in case any snag is
observed who immediately implement the instructions accordingly.
Storage
The material shall be stored under cover out of direct sunlight and protected from extreme
temperatures. Shelf life 12 months between 5 deg and 35 Celsius
Materials
De-bonding tape (to be applied before priming)
Sealant Masterflex 700 (High performance, elastomeric joint sealant)
Masterflex Primer # 1
Masterflex 700 is a high grade, synthetic rubber sealant possessing outstanding resistance to
deterioration due to weathering, ozone, ultra violet light and attack by chemicals present in
industrial atmospheres. The product has the capability to withstand repeated cycles of
compression and extension over a wide range of tempertaure range and has excellent
adhesion properties to all materials employed in buildings
Supplied in pouring and gun grade for horizontal and vertical joints respectively
Masterflex Primer # 1 is meant for porous surfaces such as concrete and masonry
Coverage Joint depth 25 mm, width 25 mm, Filling length 1.6 m per litre
Packages 3 litres sealed containers
Method
This following operational sequences shall be involved
Pre application activity
The corner area to be embedded into the sealant to be made ready with Master seal 550
Refer to Method Statement # 93
Application
Preparation of the surface required to be sealed
Taking the filler board to the required depth
Cleaning the surface and applying the de-bonding tape
Priming the surfaces
Application of the sealant up to the profile shown
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              213 of




Details
The joint area shall be prepared according to the sketch and the site conditions.
The filler shall be trimmed the the specified depth
All surfaces shall be cleaned of dust and contaminants using wire brush and made dry.
Civil Contractor QC inspection shall be conducted
The debonding tape shall be fixed as shown on the sketch
The surface shall be primed using brush according to the instructions given on the primer tins
The primer shall be allowed to dry to a tack free state before Masterflex 700 is applied within 3
hours maximum to avoid repriming
Mixing
One complete unit shall be mixed at one time without subdivision
Mixing shall be carried out for 5 to 10 minutes using a paddle fitted 500 rpm electric drill
A palette knife shall be used to scrap the container surface intermittently to ensure that all
curing agent be completely blended with the base compound.
The material shall immediately be used after mixing
Application
 The material shall be applied using a sealant gun fitted with conical nozzles adjustable to suit
the joint width by cutting
The sealant shall be gunned into the joint using an even trigger pressure and cleaning the
nozzle occasionally to avoid contamination. Deep joints shall be filled in 2 runs to prevent air
entrapment
A smaller timber spatula soaked in soapy water shall be used to compact the sealant into the
joint for a smooth polish finish formation.
The mixing and application equipment shall be cured immediately
Equipment
Paddle mixer
Sealant gun
Attachment
Manufacturer‟s statement
#84


Painting Sub stations
Top


Index
Scope
Reference documents
Definitions
Responsibilities
Safety
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              214 of



Method
Equipment
Attachment
Scope
This statement is aimed to present the proposed procedures that shall be adopted to apply the
Painting System on the above building on RCC surfaces, Galvanised surfaces,Metal surfaces,
Dry wall partition and the plastered surfaces according to the specifications and the material
system approved. A brief regarding the proposed surfaces has been mentioned below
Concrete General Wall Surfaces- Textured Epoxy Coating
Equipment Enclosure External Concrete Walls at grade level- Textured Epoxy Coating
Column Faces Features –50mm projection from general wall face with central vertical rebate-
Smooth Epoxy coating & finished
Face-horizontal band finish-50mm projection beyond wall face. Top horizontal edge to be
splayed at 45 degree-Smooth epoxy coating & finished
Vertical ribs fair face concrete face- Smooth epoxy coating & finished

Electrical Equipment / HVAC / Battery / Air Lock-
Walls- High Build Washable Acrylic Emulsion
Ceilings- High Build Emulsion
Steel doors external- Polyurethane
Galvanised external- Polyurethane
References
Notes on the Drawings & the Finishing Schedule
Specifications
MAR # Berger Paint Systems
Definitions
PSM           Project Site Manager
CSM           Construction Manager
CS            Construction Superintendent
SE            Site Engineer
FM            Foreman
QC            Quality Control
Responsibilities
PSM shall control the overall operations
CM shall arrange the resources required accordingly
CS shall control, monitor and direct the SE, FM and workforce for the operations
SE shall be responsible for all the site operations and follow the instructions of the CS
FM shall execute the operations deploying the workforce. FM shall explain in full in the
language the work persons understand about all the instruction and the ToolBox talks every
day and check that the same are followed up regularly
QC shall inspect all the operations according to the specifications


Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              215 of




EPC Contractor shall conduct surveillance
Safety
Prior to the commencement of work, the labour force shall receive a Toolbox talk relevant to
the operation concerned to the Project Site Safety requirements.
Any process that is adopted which may have a particular Safety risk shall be assessed to the
requirement for Site conditions and be taken care of.
The personnel shall use the PPE, gloves, masks, eyeglasses etc and to avoid skin contact.
use of barrier cream shall also be made.
Material safety data shall be referred to for disposal and any further information.
Adequate arrangement shall be made to provide access to the top of the wall.
Adequate scaffolding with proper netshade shall be provided wherever required
The personnel shall use the waist safety belt / harness while working on height.
Immediate medical care shall be provided in case the eyes of any personnel are effected due
to the paint splashes or any other reason
Proper ventilation shall be provided to let the workers respirate properly
A safety inspector shall visit the site every day and instruct the supervisor in case any snag is
observed who immediately implement the instructions accordingly.
Storage
The material shall be stored under cover out of direct sunlight and protected from extreme
temperatures. Shelf life 12 months between 5 deg and 35 Celsius
Materials
Specified: Texotile from Jotun or Equivalent
Approved:
Berger Paint systems
MAR # dated 27.1
The following table provides the details of the approved systems but the appropriate relevant
system shall be followed according to the scope of the work.
Appropriate arrangement adjustment shall be made for the Textured and the smooth surface
applications to the manufacturer‟s specifications / instructions
Column head –50-mm epoxy coating shall be separately stated
Table 15
S # Sub Strata                  Surface preparation                 Operating
                                                                    temperature
1     Galvanised        steel- Mechanical cleaning to remove Upto 100 deg C
      Exterior,Polyurethane loose deposits
2     Mild      steel-Exterior, Blasting to Sa 2.5                  Upto 100 deg C
      Polyurethane
3     Concrete        Surface- Cleaning with sand stone to Upto 100 deg C
      Exterior,                 smoothen the surface free from all
      Polyurethane              dirt etc
      textured
4     Galvanised        Steel- Mechanical cleaning to remove Upto 60 deg C
      Interior, Alkyd           loose deposits
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
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5           Galvanised      Steel-                       Mechanical cleaning to Sa 2 to Upto 60 deg C
            Interior,      Primed                        remove loose rust, scales
            ferrous metal Alkyd
6           Plaster and Gypsum-                          Cleaning with fine emery paper to Upto 50 deg C
            Gypsum wall board                            remove dirt etc.
            and plaster, Acrylic




Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
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                                                                                                                                              217 of




System # 1, Exterior Surfaces –Galvanised Steel, Polyurethane
Table 16
Coats    Generic      # of Solids   DFT      Colour Applicat                                                                                              Berger
         Type         coat volume Microns             ion                                                                                                 Product
                      s    %
Primer Surface        1    82       100      Alumini Brush /                                                                                              Epimast
         tolerant                            um       Spray                                                                                               ic 5100
         high build                                                                                                                                       Al
         epoxy
Finish   Gloss        1    50       50       White / Brush /                                                                                              Robbiat
         Polyurethan                         Colours Spray                                                                                                hane
         e
                      2             150




System # 2, Exterior Surfaces –Ferrous Metal, Polyurethane
Table 17
Coats                Generic                # of                  Solids                DFT                   Colour                Applicat Berger
                     Type                   coat                  volume                Microns                                     ion      Product
                                            s                     %
Primer  High                          build 1                     57                    75                    Red                   Brush                 Epilux
        epoxy                                                                                                                       /                     78
        polyamide                                                                                                                   Spray
        primer
Interme High build 1                                              68                    100                   Grey    Brush                               Epilux
diate   epoxy                                                                                                         /                                   218HS
        polyamide                                                                                                     Spray
Finish  Gloss       1                                             50                    50                    White / Brush                               Robbiat
        Polyurethan                                                                                           Colours /                                   hane
        e                                                                                                             Spray
                    3                                                                   225

Touch up if required with Epilux 78 after power tool cleaning on spots




Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              218 of




System # 3, Exterior Surfaces –Concrete Masonry, Polyurethane Textured
Table 18
Coats                Generic                        # of          Solids                DFT                   Colour                Applicat Berger
                     Type                           coat          volume                Microns                                     ion      Product
                                                    s             %
Primer               Epoxy                          1             45                    50                    White                 Brush / Epilux
                     Concrete                                                                                                       Spray / Concret
                                                                                                                                    Roller   e
                                                                                                                                             Primer
Interme Epoxy        1                                            68                    1000                  White                 Hopper Luxatile
diate   spray                                                                                                                       Gun      Epoxy
        compound                                                                                                                             Spray
        in textured                                                                                                                          Compo
        finish                                                                                                                               und
Finish  Gloss      / 1                                            50                    50                    White                 Roller / Robbiat
        Semi Gloss                                                                                            /                     Spray    athane
        Polyurethan                                                                                           Colours
        e
                                                                                        1100

The textured pattern is unpressed and the DFT could vary from 700 to 1000
micron or more as manually applied by hopper gun. Appropriate instruction to
apply the smooth coat
shall be followed according to the manufacturer‟s manual

System # 4, Interior Surfaces –Galvanised Steel, Alkyd
Table 19
Coats                Generic                        # of Solids                         DFT                   Colour                Applicat Berger
                     Type                           coat volume                         Microns                                     ion      Product
                                                    s    %
Etch      Two    Pack 1                                           8.5                   5                     Greenish              Brush           / Luxaprim
Primer(T washer                                                                                               Yellow                Spray             e 1500
o      be primer
used in
surface
preparati
on
instead
of
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
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                                                                                                                                              219 of




blasting)
Coats                Generic                        # of Solids                         DFT                   Colour                Applicat Berger
                     Type                           coat volume                         Microns                                     ion      Product
                                                    s    %
Primer    Anticorrosive 1                                         55                    55                    Red                   Brush           / Luxaprim
Coat      rust inhibitive                                                                                                           Spray             e 1500
          Primer
Intermedi Alkyd           1                                       55                    55                    White   Brush                         / Luxole
ate Coat Undercoat                                                                                                    Spray                           1000
Finish    Alkyd Enamel 1                                          48                    48                    White / Brush                         / Luxole
Coat                                                                                                          Colours Spray                           5000
                          4                                                             155

Luxaprime 1000 has to be applied on the same day of Luxaprime 1500


System # 5, Interior Surfaces –Primed Ferrous Metal, Alkyd
Table 20
Coats                Generic                        # of Solids   DFT                                             Colour                Applicat Berger
                     Type                           coat volume % Microns                                                               ion      Product
                                                    s
Primer     High    build 1                                        50                        50                    Red              / Brush               / Luxaprim
Coat(If    alkyd    zinc                                                                                          Grey               Spray                 e 1400
required)  phosphate
           primer
Intermedi Alkyd          1                                        55                        50                    White   Brush                          / Luxol
ate Coat undercoat                                                                                                        Spray                            1000
Finish     Alkyd Enamel 1                                         50                        50                    White / Brush                          / Luxol
Coat                                                                                                              Colours Spray                            5000
Note-                    3                                                                  150
Primer
need not
be
applied if
already
primed




Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              220 of




System # 6, Interior Surfaces –Gypsum Wallboard and plaster, Acrylic
Table 21
Coats                Generic                        # of Solids                         DFT                   Colour                Applicat Berger
                     Type                           coat volume                         Microns                                     ion      Product
                                                    s    %
Primer               Premium                        1             25                    25                    White                 Brush   / Brolac
Coat                 quality alkali                                                                                                 Roller    Acrylic
                     resisting                                                                                                                AR
                     primer                                                                                                                   Primer
Filler               High quality           1(to                  81                    To        White                             Spatula   Berger
Coat                 acrylic based          seal                                        smoothe                                               Super
                     wall filler            &                                           n     the                                             Wall
                                            smo                                         surface                                               Filler
                                            othe
                                            n
                                            the
                                            surf
                                            ace)
Intermedi High                      quality 1                     35                    50                    White / Roller                              Bergerco
ate Coat acrylic                                                                                              Colours                                     at Acrylic
          emulsion                                                                                                                                        Emulsion
Finish    Semi    gloss 1                                         35                    50                    White / Roller                              Brolac
Coat      acrylic                                                                                             Colours                                     Semi
          emulsion                                                                                                                                        Gloss
                                                                                                                                                          Emulsion
                                                    3                                   >100

Method
GENERAL
Marking of containers
Materials shall be delivered in sealed containers clearly labelled with the following information.
Manufacturer‟s name, initials or recognised trade mark
Title and specification number
Whether primer or undercoat, finishing coat
Whether for internal or external use where appropriate
Colour reference from BS 4800
Method of application
Batch number and date of manufacture and re – test
No paint shall be used after 18 months of manufacture or re test
Coating materials other than spray paints, bituminous pants and fine textured masonry paint
shall be in containers not exceeding 5 litres capacity


Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
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                                                                                                                                              221 of




Samples
Sample panel of 1 sqm in area shall be prepared for each type and colour of coating material
to be used in the work for the approval
Sample material of each paper / fibre material minimum size 500 x 500 mm showing at least
the pattern repeat where applicable shall be submitted for approval
Part 2
Materials
Preparatory Materials
Paint removers, abrasive papers and blocks, cleaning agents, etching solutions, stopping,
knotting, fillers and other commodities shall be of the types recommended by the manufacturer
of the coating to be applied
White spirit shall comply with BS 245
Knotting shall comply with BS 1336
Stopping and filler for woodwork shall be approved proprietary Leadless oil based type
recommended for internal or external work as appropriate. Stopping for woodwork to receive a
coat finish shall be tinted to match with the surrounding work
Filler for plaster or rendering shall be approved proprietary type
The following operational sequences shall be involved
Priming Coat
Filler Coat to the requirement
Intermediate Coat
Finishing Coat
All according to the approved system as aforesaid detailed for reference.
Application
PREPARATION OF THE GALVANIZED SURFACES
Dirt and other adherent contaminating matter / loose deposits shall be removed from
galvanised surfaces by mechanical means using Berger tool cleaner. Cleaning shall not
damage the galvanising. Oil or grease shall be removed from galvanised surfaces by the
application of an emulsion cleaner. Any zinc corrosion products remaining shall be removed by
washing with sweet water and scrubbing with hard bristle brushes
After being cleaned and degreased, all galvanised surfaces shall be etched with T-wash as
described in BS 5493. If any surface fails to turn black as cleaning, greasing and etching
processes shall be repeated.
APPLICATION OF PAINT GENERALLY
All paints shall be prepared and applied in strict accordance with the manufacturer‟s
instructions. Priming paints shall be applied by brush. Spray application shall only be used for
painting of epoxy resin base
Exposure of intermediate coats of paint for periods in excess of a few days shall not be
permitted except in case of work delivered to site in a primed condition
The dried films shall be free from bloom, shrinkage, sheeringness, wrinkling, sagging,
curtailing, discoloration and extraneous matter
No exterior or exposed paint work shall be carried out under adverse weather conditions,
during rain, mist, sandstorms nor when the relative humidity exceeds 80%

Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
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Painting shall insofar as is practicable be shaded from direct sunlight by netting to prevent
wrinkling and bristling. Whenever possible exterior painting shall be so programmed during the
day so as to be carried out in shadow
Painting of surfaces shall not be carried out when condensation is present on such surfaces or
the application and / or drying of the paints is likely to be affected
Surfaces to be painted shall receive as first coat of paint as quickly as possible after the e
preparation has been completed
In case of metal surfaces this shall preferably be within one hour but always before the metal
temperature drops to less than 3 deg C above dew point and before any rusting
Civil Contractor QC inspections shall be conducted at every stage of surface preparation , post
application of the coat, prior to the proceeding and at the final coat completion followed by
EPC Contractor approval all according to the ITP documents attached
METHOD OF COATING
Each coat shall be applied uniformly over the entire surface. Skips, runs, sags and drips shall
be avoided. When these occur they shall be brushed out immediately or the materials
removed and the surface recoated. On beams and irregular surfaces, edges shall be strip
coated first and at extra pass made later. Each coat shall be allowed to dry for the time
specified by the manufacturer before application of any succeeding coat
Any primer coat exposed to freezing, excess humidity, rain, dust etc., before drying, shall be
removed, surface again prepared and primed
The time interval between application of coats shall not exceed that specified for optimum
results by the manufacturer
All coatings shall be cleaned as specified by the manufacturer before the next coat is applied
All areas not specifically mentioned in the painting specification shall be finished to conform to
the adjacent comparable areas
All fixtures and surfaces not to be painted shall be properly protected during application and
upon completion of the work all paint and varnish removed from glass, fixtures, covering, etc.,
Moveable parts shall not to be painted.
All parts such as pipe supports, seatings and cleats, back to back sections which shall become
inaccessible after fabrication shall be treated on both surfaces with the full paint system prior to
final assembly, thus ensuring adequate protection.
SPRAY APPLICATION
All equipment for spray application shall be inspected and approved before any application
begins. Spray guns, hoses and pumps shall be cleaned before new material is added. An
adequate moisture and oil trap shall be installed between the air supply to each application
unit.
Suitable pressure regulators and gauges shall be provided for the air supply to the application
units. Spray equipment and operating pressures shall comply with the manufacturer‟s
recommendations.
Coating materials containing heavy pigments that have a tendency to settle shall be kept in
suspension during the application by the power driven, continuous agitator
The spray gun shall be held at right angles to the surface and each pass overlap the previous
one by approximately 50%. All materials contained herein may be applied by airless spray.

Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
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BRUSH APPLICATION
Brushes shall be of a style and quality that permit proper application of the material
Flat brushes shall not be more than 100 mm wide. No extending handles shall be used on
brushes.
Brushing shall be done so that a smooth coat as nearly uniform in thickness as possible is
obtained without any deep or detrimental marks
Paints shall be worked into all corners and crevices.
When applying solvent type coating, care shall be taken to prevent lifting of previous coats.
FILM THICKNESS
Specified film thickness for coating materials shall be strictly observed which be checked with
an appropriate film thickness gauge. Calibration for the thickness range to be checked at least
twice a day
When dry film thickness are less than those specified, additional coats shall be applied as
required. Particular attention shall be paid to full film thickness on edges
In hot weather such additional precautions as are necessary shall be taken to ensure that the
specified dry film thickness on priming or finish coats is obtained
COATING QUALITY
Coatings shall be free from pinholes, voids, bubbles, dust, foreign inclusions and other
holidays and any such defect shall be repaired. Prior to the application of a coating, any
damage to the previous coating shall be repaired with the specified material. Upon completion
of the fabrication any damage to the coating system shall be repaired
TEST EQUIPMENT
Svensk photographic standard SIS 05 59 00
Coating thickness meter such as Elcometer „Minitector” Model 150
Wet fill thickness combs
Hygrometer
Maximum and minimum thermometer
Flow cup type B # 4 and timer
Surface profile meter such as Elcometer‟Roughness detector‟
Bolted site connections other than faying surfaces of Grip Bolt connections shall be brought
together „wet‟
EPOXY COATING WORK GENERALLY
In addition to the general requirements the following conditions shall apply wherever epoxy-
coating work is being carried out
Forced draught ventilation shall be used wherever required for the needs of the personnel or
for drying out surfaces
Operatives shall work in pairs
Samples areas on substrate shall be prepared and coated for approval
There shall be strict control of surface cleanliness between primer and epoxy coating / and
between coats of the same. Vacuum removal of dust and sand shall be employed and
contamination removed. Where dirt or dust has been trapped in the painted surface it shall be
removed with suitable abrasive paper. The surface being painted shall be free of visible
moisture throughout these operations

Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              224 of



The paint shall be applied only to the clean dry primed or previously coated surfaces. Any thick
runs or collections of paint shall be removed before these harden
Not less than 2 coats shall be applied over the primer by airless spray, less than 3 by brush
Each coat shall be distinctly different in colour from the primer or previous coat. The colour of
the final coat shall be as approved. Each coat shall be seen to have completely covered the
proceeding without „ misses‟ or pinholes or any areas visibly low in thickness. A high voltage
pinhole detector shall also be used to determine the integrity of the coats
The manufacturer of the coating shall stipulate primer and epoxy recoat interval for all curing
temperatures likely to be encountered and these be adopted with a maximum tolerance of +4
hours. Where this is exceeded, the surfaces to be recoated shall first be suitably abraded to
remove gloss and provide a key
Wet thickness gauges shall be used by the coating operators continually to check that
sufficient paint is being applied to achieve the desired dry film thickness
EPOXY COATING FOR CONCRETE AND RENDERED SURFACES
No priming shall commence until the moisture content of the cementitious surface is less than
5% measured by Wetcheck Moisture meter or other instrument
Similarly moisture measurements over the primer or any epoxy intercoat shall not exceed 1 %
on the concrete scale of the instrument when the probe tips are held against such painted
surfaces just prior to recoating
The priming shall be applied by suitable Nylon bristle brush or spray over the whole area to be
coated at such thickness that it may then be squeezed into the pores of the concrete. Any
excess shall be removed by the most suitable means before application of the high build epoxy
The total DFT of the paint layer shall have a minimum specified value
Whenever the paint inspection gauge has been used and wherever the coating has been
otherwise damaged for 50 mm around such damage, the surfaces shall be abraded followed
by the area touched in with not less than 2 # thick applications to restore the coating integrity
to the specified thickness.
Adhesion tests shall be carried out on the cured coating surface using the test equipment
supplied in accordance with the best practice. The resulting test specimens shall show no
indication of poor adhesion to the substrate, residual laitance or intercoat adhesion weakness.
The following instrument shall be used
1 Adhesion Tester 0 to 35 kg / cm2
1 DC high voltage holiday detector # 105
One paint inspection gauge PIG
1 wet check moisture meter
Equipment
Spray appliance
Brushes
Rollers
Attachment
ITP-Doc: QCF Rev B
Concrete paint system checklist
ITP-Doc :QCF Rev B
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              225 of



Internal painting check list
#85


Painting Sub stations
Top
Index
Scope
Reference documents
Definitions
Responsibilities
Safety
Method
Equipment
Attachment
Scope
This statement is aimed to present the procedures to be adopted to apply the Painting System
on the various surfaces of all the Sub Station buildings according to the following specifications
and the drawing references
References
Specifications
Definitions
PSM           Project Site Manager
CSM           Construction Manager
CS            Construction Superintendent
SE            Site Engineer
FM            Foreman
QC            Quality Control
Responsibilities
PSM shall control the overall operations
CM shall arrange the resources required accordingly
CS shall control, monitor and direct the SE, FM and workforce for the operations
SE shall be responsible for all the site operations and follow the instructions of the CS
FM shall execute the operations deploying the workforce. FM shall explain in full in the
language the work persons understand about all the instruction and the ToolBox talks every
day and check that the same are followed up regularly
QC shall inspect all the operations according to the specifications
Safety
Prior to the commencement of work, the labour force shall receive a
STARRT Card / Toolbox talk regarding the painting system operation concerned to the
Project Site Safety requirements.
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              226 of



Any process involving a particular Safety risk shall be assessed to the requirement for Site
conditions and be taken care of. In this case all the adverse effects of the epoxy paint shall be
informed and the safety measures to be adopted instructed.
The personnel shall use the PPE, gloves, masks, eyeglasses etc and to avoid skin contact.
use of barrier cream shall also be made.
Material safety data shall be referred to for disposal and any further information.
Adequate arrangement shall be made to provide access up to the top of the wall.
Tagged scaffolding with proper netshade shall be provided wherever required
The personnel shall use the waist safety belt / harness while working height.
Immediate medical care shall be provided in case the eyes of any personnel are effected due
to the paint splashes or any other reason
Proper ventilation shall be provided to breathe properly
A safety inspector shall visit the site every day and instruct the supervisor in case any snag is
observed who immediately implement the instructions accordingly.
Storage
The material shall be stored under cover out of direct sunlight and protected from extreme
temperatures.
Materials
Specified: Texotile from Jotun or Equivalent
Approved: Berger Paint systems MAR dated 27.1.
The following table provides the details of the approved systems
Table 22
S # Sub Strata                   Surface preparation                     Operating
                                                                         temperature
1      Galvanised        steel- Mechanical cleaning to remove Upto 100 deg C
       Exterior,Polyurethane loose deposits –Cleaning with
                                 Berger        Cleaner-Refer        to
                                 manufacturer‟s recommendations
2      Mild      steel-Exterior, Blasting to Sa 2.5                      Upto 100 deg C
       Polyurethane
3      Concrete        Surface- Cleaning with sand stone to Upto 100 deg C
       Exterior,                 smoothen the surface free from all
       Polyurethane              dirt etc
       textured
4      Galvanised        Steel- Mechanical cleaning to remove Upto 60 deg C
       Interior, Alkyd           loose deposits - Cleaning with
                                 Berger      Cleaner     -Refer     to
                                 manufacturer‟s recommendations
5      MS / Ferrous Metal- Mechanical cleaning to Sa 2 to Upto 60 deg C
       Interior,                 remove loose rust, scales
       Primed ferrous metal
       Alkyd
6      Plaster and Gypsum- Cleaning with fine emery paper to Upto 50 deg C
       Gypsum wall board remove dirt etc.
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              227 of




            and plaster, Acrylic

System # 1, Exterior Surfaces –Galvanised Steel, Polyurethane
Table 23
Coats    Generic      # of Solids   DFT       Colour Applicat                                                                                             Berger
         Type         coat volume   Microns            ion                                                                                                Product
                      s    %
Primer Surface        1    82       100       Alumini Brush /                                                                                             Epimast
         tolerant                             um       Spray                                                                                              ic 5100
         high build                                                                                                                                       Al
         epoxy
Finish   Gloss        1    50       50        White / Brush /                                                                                             Robbiat
         Polyurethan                          Colours Spray                                                                                               hane
         e
                      2             150
System # 2, Exterior Surfaces –Ferrous Metal, Polyurethane
Table 24
Coats                Generic                # of                  Solids                DFT                   Colour                Applicat Berger
                     Type                   coat                  volume                Microns                                     ion      Product
                                            s                     %
Primer  High                          build 1                     57                    75                    Red                   Brush                 Epilux
        epoxy                                                                                                                       /                     78
        polyamide                                                                                                                   Spray
        primer
Interme High build 1                                              68                    100                   Grey    Brush                               Epilux
diate   epoxy                                                                                                         /                                   218HS
        polyamide                                                                                                     Spray
Finish  Gloss       1                                             50                    50                    White / Brush                               Robbiat
        Polyurethan                                                                                           Colours /                                   hane
        e                                                                                                             Spray
                    3                                                                   225
Touch up shall be carried out with „Epilux 78‟ after cleaning the effected area using power tool




Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              228 of




System # 3, Exterior Surfaces –Concrete Surface / Masonry, Polyurethane
Textured
Table 25
Coats                Generic                        # of          Solids                DFT                   Colour                Applicat Berger
                     Type                           coat          volume                Microns                                     ion      Product
                                                    s             %
Primer               Epoxy                          1             45                    50                    White                 Brush / Epilux
                     Concrete                                                                                                       Spray / Concret
                                                                                                                                    Roller   e
                                                                                                                                             Primer
Interme Epoxy        1                                            68                    1000                  White                 Hopper Luxatile
diate   spray                                                                                                                       Gun      Epoxy
        compound                                                                                                                             Spray
        in textured                                                                                                                          Compo
        finish                                                                                                                               und
Finish  Gloss      / 1                                            50                    50                    White                 Roller / Robbiat
        Semi Gloss                                                                                            /                     Spray    athane
        Polyurethan                                                                                           Colours
        e
                     3                                                                  1100

Because the textured pattern is unpressed the DFT may vary from 700 to 1000
micron or more as manually applied by hopper gun.
The smooth surface shall be produced by following the relevant manufacturer‟s
instruction

System # 4, Interior Surfaces –Galvanised Steel, Alkyd
Table 26
Coats                      Generic                  # of Solids                         DFT                   Colour                Applicat Berger
                           Type                     coat volume                         Microns                                     ion      Product
                                                    s    %
Etch        Two Pack 1                                            8.5                   5                     Greenish              Brush           / Luxaprim
Primer(To   wash                                                                                              Yellow                Spray             e 1500
be used in primer
surface
preparation
instead of
blasting)

Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              229 of




Coats                      Generic                  # of Solids                         DFT                   Colour                Applicat Berger
                           Type                     coat volume                         Microns                                     ion      Product
                                                    s    %
Primer Coat                Anticorrosi 1                          55                    50                    Red                   Brush           / Luxaprim
                           ve       rust                                                                                            Spray             e 1500
                           inhibitive
                           Primer
Intermediat                Alkyd         1                        55                    50                    White   Brush                         / Luxole
e Coat                     Undercoat                                                                                  Spray                           1000
Finish Coat                Alkyd         1                        48                    50                    White / Brush                         / Luxole
                           Enamel                                                                             Colours Spray                           5000
                                         4                                              155

Luxaprime 1000 primer coat shall be applied the same day when the surface is prepared by
etching using Luxaprime 1500

System # 5, Interior Surfaces –Primed Ferrous Metal, Alkyd
Table 27
Coats                Generic                        # of Solids   DFT                                             Colour                Applicat Berger
                     Type                           coat volume % Microns                                                               ion      Product
                                                    s
Primer     High    build 1                                        50                        50                    Red              / Brush               / Luxaprim
Coat(If    alkyd    zinc                                                                                          Grey               Spray                 e 1400
required)  phosphate
           primer
Intermedi Alkyd          1                                        55                        50                    White   Brush                          / Luxol
ate Coat undercoat                                                                                                        Spray                            1000
Finish     Alkyd Enamel 1                                         50                        50                    White / Brush                          / Luxol
Coat                                                                                                              Colours Spray                            5000
Note-                    3                                                                  150
Primer
need not
be
applied if
already
shop
primed




Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              230 of




System # 6, Interior Surfaces –Gypsum Wallboard and plaster, Acrylic
Table 28
Coats                Generic                        # of Solids                         DFT                   Colour                Applicat Berger
                     Type                           coat volume                         Microns                                     ion      Product
                                                    s    %
Primer               Premium                        1             25                    25                    White                 Brush   / Brolac
Coat                 quality alkali                                                                                                 Roller    Acrylic
                     resisting                                                                                                                AR
                     primer                                                                                                                   Primer
Filler               High quality           1(to                  81                    To        White                             Spatula   Berger
Coat                 acrylic based          seal                                        smoothe                                               Super
                     wall filler            &                                           n     the                                             Wall
                                            smo                                         surface                                               Filler
                                            othe
                                            n
                                            the
                                            surf
                                            ace)
Intermedi High                      quality 1                     35                    50                    White / Roller                              Bergerco
ate Coat acrylic                                                                                              Colours                                     at Acrylic
          emulsion                                                                                                                                        Emulsion
Finish    Semi    gloss 1                                         35                    50                    White / Roller                              Brolac
Coat      acrylic                                                                                             Colours                                     Semi
          emulsion                                                                                                                                        Gloss
                                                                                                                                                          Emulsion
                                                    3                                   >100


Method
GENERAL
Materials shall be delivered in sealed containers clearly labelled with the following information.
Manufacturer‟s name or recognised trade mark
Title and specification number
Whether primer or undercoat, finishing coat
Whether for internal or external use where appropriate
Colour reference from BS 4800
Method of application
Batch number and date of manufacture
Samples
Sample panel of 1 sqm in area shall be prepared for each type of coating for approval on any
of the surfaces to be applied with that paint
The following operational sequences shall be involved
Priming Coat
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              231 of



Filler Coat to the requirement
Intermediate Coat
Finishing Coat
All according to the approved system as aforesaid
Application
PREPARATION OF THE GALVANIZED SURFACES
Dirt and other adherent contaminating matter / loose deposits shall be removed from
galvanised surfaces by mechanical means using Berger tool cleaner. Cleaning shall not
damage the galvanising.
APPLICATION OF PAINT (GENERAL)
All paints shall be prepared and applied in strict accordance with the manufacturer‟s
instructions.
Exposure of intermediate coats of paint for periods in excess of specified time shall not be
permitted except in case of work delivered to site in a primed condition
The dried films shall be free from all defects such as bloom, shrinkage, sheerings, wrinkling,
sagging, curtailing, discoloration and extraneous matter
No exterior or exposed paintwork shall be carried out under adverse weather conditions i.e.,
during neither sandstorms nor when the relative humidity exceeds 80%
Painting shall insofar as is practicable be shaded from direct sunlight by netting to prevent
wrinkling and bristling.
Painting of surfaces shall not be carried out when condensation is present on such surfaces or
the coating application on drying is likely to be affected
Surfaces to be painted shall receive the first coat of paint as quickly as possible after the
preparation has been completed
In case of metal surfaces, this shall preferably be within one hour but always before the metal
temperature drops to less than 3 deg C above dew point and before any rusting
Civil Contractor QC inspections shall be conducted at every stage of surface preparation, post
application of the coat, prior to the proceeding coat and at the final coat completion, all
according to the ITP documents attached
METHOD OF COATING
Each coat shall be applied uniformly over the entire surface. Skips, runs, sags and drips shall
be avoided. When these do occur, they shall be brushed out immediately or the materials
removed and the surface recoated. On beams and irregular surfaces, edges shall be strip
coated first and an extra pass made later. Each coat shall be allowed to dry for the time
specified by the manufacturer before application of any succeeding coat
Any primer coat exposed to, excessive humidity, dust etc., before drying, shall be removed,
and the surface again prepared and primed
All coatings shall be cleaned as specified by the manufacturer before the next coat is applied
All fixtures and surfaces not to be painted shall be properly protected during application and
upon completion of the work all paint and varnish removed from glass, fixtures, covering, etc.,
Moveable parts shall not to be painted.
All parts such as pipe supports, seatings and cleats, back to back sections which shall become
inaccessible after fabrication shall be treated on both surfaces with the full paint system prior to
final assembly, thus ensuring adequate protection.
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              232 of



SPRAY APPLICATION
All equipment for spray application shall be inspected and approved before any application
begins. Spray guns, hoses and pumps shall be cleaned before new material is added. An
adequate moisture and oil trap shall be installed between the air supply to each application
unit.
Suitable pressure regulators and gauges shall be provided for the air supply to the application
units. Spray equipment and operating pressures shall comply with the manufacturer‟s
recommendations.
Coating materials containing heavy pigments that have a tendency to settle shall be kept in
suspension during the application by the power driven, continuous agitator
The spray gun shall be held at right angles to the surface and each pass overlap the previous
one by approximately 50%. All materials contained herein may be applied by airless spray.
BRUSH APPLICATION
Brushes shall be of a style and quality that permit proper application of the material
No extending handles shall be used on brushes.
Brushing shall be done so that a smooth coat as nearly uniform in thickness as possible is
achieved without any deep or detrimental marks
Paints shall be worked into all corners and crevices.
FILM THICKNESS
Specified film thickness for coating materials shall be strictly observed which is checked with
an appropriate „film thickness gauge‟.
When dry film thickness is less than that specified, additional coats shall be applied as
required. Particular attention shall be paid to full film thickness on edges
In hot weather such additional precautions as are necessary shall be taken to ensure that the
specified dry film thickness on priming or finishing coats is achieved by monitoring the wet film
thickness using the appropriate gauge. Additional coats shall be applied on the deficient area
COATING QUALITY
Coatings shall be free from pinholes, voids, bubbles, dust, foreign inclusions and other
holidays and all such defects shall be repaired. Prior to the application of a coating, any
damage to the previous coating shall be repaired with the specified material.
TEST EQUIPMENT
Coating thickness meter such as Elcometer „Minitector” Model 150 or equivalent
Wet fill thickness combs
Hygrometer
Maximum and minimum thermometer
Surface profile meter such as Elcometer‟Roughness detector‟
EPOXY COATING WORK (GENERAL)
In addition to the general requirements the following conditions shall apply wherever epoxy-
coating work is being carried out
Forced draught ventilation shall be used wherever required for the needs of the personnel or
for drying out surfaces
Operatives shall work in pairs
Sample on substrate shall be prepared and coated for approval

Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              233 of



There shall be strict control of surface cleanliness between primer and epoxy coating / and
between coats of the same application. Vacuum removal of dust and sand shall be employed
and contamination removed. Where dirt or dust has been trapped in the painted surface, it
shall be removed with suitable abrasive paper. The surface being painted shall be free of
visible moisture throughout these operations
The paint shall be applied only to the clean & dry primed or previously coated surfaces. Any
thick runs or collections of paint shall be removed before these harden
Each coat shall be distinctly different in colour from the primer or previous coat. The colour of
the final coat shall be as approved. Each coat shall be seen to have completely covered the
proceeding without „ misses‟ or pinholes or any areas „visibly low‟ in thickness. A high voltage
pinhole detector shall also be used to determine the integrity of the coats
“The manufacturer of the coating shall stipulate primer and epoxy recoat interval for all curing
temperatures likely to be encountered and these be adopted with a maximum tolerance of +4
hours”. Where this is exceeded, the surfaces to be recoated shall first be suitably abraded to
remove gloss and provide a key
Wet thickness gauges shall be used by the coating operators continually to check that
sufficient paint is being applied to achieve the desired dry film thickness
EPOXY COATING FOR CONCRETE AND RENDERED SURFACES
No priming shall commence until the moisture content of the cementitious surface is less than
5% measured by Wetcheck Moisture meter or other instrument
Similarly moisture measurements over the primer or any epoxy intercoat shall not exceed 1 %
on the concrete scale of the instrument when the probe tips are held against such painted
surfaces just prior to recoating
The priming shall be applied by suitable Nylon bristle brush or spray over the whole area to be
coated at such thickness that it may then be squeezed into the pores of the concrete. Any
excess shall be removed by the most suitable means before application of the high build epoxy
The total DFT of the paint layer shall have a minimum specified value
Whenever the paint inspection gauge has been used and wherever the coating has been
otherwise damaged, the surfaces shall be abraded 50 mm around and the area touched in with
not less than 2 # thick applications to restore the coating integrity to the specified thickness.
Adhesion tests shall be carried out on the cured coating surface using the test equipment
supplied in accordance with the best practice. The resulting test specimens shall show no
indication of poor adhesion to the substrate, residual laitance or intercoat adhesion weakness.
The following instrument shall be used
1 Adhesion Tester 0 to 35 kg / cm2
1 DC high voltage holiday detector # 105
One paint inspection gauge PIG
1 wet check moisture meter
Equipment
Spray appliance
Brushes
Rollers


Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              234 of



Attachment
ITP-Doc: QCF Rev B
Concrete paint system checklist
ITP-Doc :QCF Rev B
Internal painting check list
#86


Electrical & instrumentation
trenches
Top
Index
Scope
Reference documents
Definitions
Responsibilities
Safety
Method
Equipment
Attachment
Scope
This statement is aimed to present the proposed procedures to be adopted to carry out the
construction of the proposed Electrical and Instrumentation trenches to the following specified
details
Cable trench X-ing with U / G pipe
Cable trench X-ing with U / G pipe with closed drain pipe trench
Pipe X-ing direct buried cables only
Typical elctrical layout at pumps
Typical corner details for walled trench
Direct buried trench X-ing under Dummy Trench
Trench with dummy Trench X-ing under direct buried cable trench
Dummy + walled trench section
References
paving & Under Ground services
Electrical and Instrumentation Trench and Duct Bank details
Specifications
Definitions
PSM           Project Site Manager
CSM           Construction Manager
CS            Construction Superintendent
SE            Site Engineer
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              235 of



FM                       Foreman
QC                       Quality Control
Responsibilities
PSM shall control the overall operations
CM shall arrange the resources required accordingly
CS shall control, monitor and direct the SE, FM and workforce for the operations
SE shall be responsible for all the site operations and follow the instructions of the CS
FM shall execute the operations deploying the workforce. FM shall explain in full in the
language the work persons understand about all the instruction and the ToolBox talks every
day and check that the same are followed up regularly
QC shall inspect all the operations according to the specifications
EPC Contractor shall conduct surveillance
Safety
Prior to the commencement of work, the labour force shall receive a Toolbox talk relevant to
the operation concerned to the Project Site Safety requirements.
Any process that is adopted which may have a particular Safety risk shall be assessed to the
requirement for Site conditions and be taken care of.
The personnel shall use the PPE, gloves, masks (for gas leak in area), eyeglasses (during
dusty winds) etc
Adequate arrangement shall be made to provide access to the top of the wall.
A safety inspector shall visit the site every day and instruct the supervisor in case any snag is
observed who immediately implement the instructions accordingly.
Materials
Mass Concrete for strip foundation beam, Concrete blocks, precast covers, oil resistant sealant
Method
GENERAL-Dummy and walled trench section
The following operational sequences shall be involved
To set out the exact alignment of the trenches to the specified co-ordinates
To barricade the involved area to the safety requirement
To excavate the trenches to the specified levels
To dress the formations and compact
To prepare the sides for the mass concrete 100mm thick
To pour the mass concrete
To set out the block walls alignment
To carry out 150mm thick block work to the specified levels upto the paving down beam level
To carry out the down standing paving portion & extend to the block wall top
To fill the trench with the excavated earth back according to specifications
To place the precast coloured concrete covers 1m or 3m lengths on the compacted ground
To Seal the paving and cover joint

Where the dummy trench runs over the duct bank (Typical Trench Duct Bank Detail)


Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              236 of



The duct bank with the uPVC sleeves in for the crossing portion below the underground pipe
should be ready formed with the mass concrete the size of which shall vary according to the
number of crossing pipes
The following operational sequences shall be involved
To excavate down to the top of the duct concrete in case backfilling has been completed
To clean the concrete surface
To set out the trench alignment
To set out the block wall alignment keeping maximum 50 mm overhang
To construct the block walls to paving down beam level
To carry out the down standing paving portion & extend to the block wall top
To fill the trench with the excavated earth back according to specifications
To place the precast coloured concrete covers 1m or 3m lengths on the compacted ground
To Seal the paving and cover joint
Additionally, in case the underground pipe runs X-ing the Trench, to lay the specified pipe prior
to the block work operation by others
To provide a flat crossing size equal (Duct Bank length + 300x2)
The formation level of the duct bank and the dummy trench shall be the same at the exact
crossing location
Where the dummy trench and the direct buried trench run parallel
The following operational sequences shall be involved
To repeat all the sequences as in general in the aforesaid
To follow the profile of the dummy trench while constructing the buried trench for ease
To form the down slope profile at the crossings as shown on the drawing
The slope grade shall be 1 in 2
Where the cable trench crossing the closed drain pipe trench
The following additional operational sequences to the general trench construction for the
dummy or the direct buried shall be required
To provide the profile of the direct buried trench same as that of the cable duct trench
To provide the transition of levels between the dummy trench and the flat below X-ing by a
slope grade 1 in 2 as specified on the drawing
To provide a duct bank of size depending on the dimension of the closed drain trench to pass
above by providing a width (closed drain trench width + 100mmx2)
To provide a total flat width below the crossing equal (duct bank length + 300x2).
To provide the uPVC sleeves in the duct bank prior to the mass concreting
To allow a clear void of 100mm minimum between soffit of closed drain trench base and the
duct bank top
To provide cable tiles under trench crossing in direct buried cable trenches only(By others)
To allow the closed drain trench isolate from the paving
Where direct buried trench crossing under dummy trench
The following additional operational sequences to the general trench construction for the
dummy or the direct buried shall be required
To provide a level difference of 350 mm between the dummy trench elevation and the
compacted surface below the crossing maintaining a transition slope grade 1 in 2

Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              237 of



To allow the cables running in dummy trench to be protected by the cable tiles installed at 75
mm above the top of cables where no paving is shown (By others)
To allow to provide the cable protection tiles above the cables where these pass in the walled
trench to cross under the dummy trench (By others)
To form the walled trench corner detail according to the corner splay internal size 8485 mm
Where dummy Trench crossing under direct buried cable trench
The following additional operational sequences to the general trench construction for the
dummy or the direct buried shall be required
To provide a flat surface below the X-ing at the bottom of the duct bank of size equal (duct
bank length + 300x2) with a slope grade transition 1 in 2
To provide a level difference of 100 mm between soffit of the direct burried cable trench and
the duct bank top
Where direct buried cable trench crossing under direct buried cable trench
The following additional operational sequences to the general trench construction for the
dummy or the direct buried shall be required
To maintain a level difference 700 mm between direct buried trench and the crossing formation
level
To provide a transition grade 1 in 2
To provide a cable tiles in unpaved areas only and at trench crossing (By others)
To provide the formation crossing width equal (direct buried cable trench width + 400x2)
Electric Trench Layout at Pumps
The following additional operational sequences to the general trench construction for the
dummy or the direct buried shall be required
To form the trench termination into an integral chamber of internal dimensions as
(Pump base length / 2+trench internal width) x (Pump base width +300+500)
Details in general
The surveyor shall setout the alignment of the trench concerned according to the details given
on the paving and underground services layouts to the reference co-ordinates
Civil Contractor QC shall conduct the inspection followed by EPC Contractor approval
The required safety arrangement shall be discussed with the safety department and
implemented accordingly to control the trench excavation, to provide barricades night-lights
etc, to divert the traffic if so required and to adopt any other unforeseen measures.
The excavation shall be carried out by an excavator to the lines and the surveyor monitor
various stages during the operation to maintain the required profile
The excavated material shall be transported immediately after being taken out using a dumper,
to the earth stockpiles temporarily
The formation levels after the excavation is over shall be well dressed and compacted to the
specification requirement
The forms of width 350mm and depth 100 mm shall be readily available to be fixed on the
prepared compacted formation duly aligned
Civil Contractor QC inspection shall be conducted followed by EPC Contractor approval
The mass concrete shall be poured to the marked levels and tamped by wooden float
The curing shall be carried out according to approved procedures

Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              238 of



The alignment of the block walls 150 mm thick shall be set out, the block work carried out in
courses in a straight line and plumb
The whole number of courses shall be laid, the fraction remained to be completed for the wall
height shall be covered by pouring during the paving down beam concrete
The connecting integrated / pouring area including the down beam shall be carried out to the
specified details according to the procedures
Civil Contractor QC inspection shall be conducted followed by the EPC Contractor approval
The backfilling shall commence and the trench filled according to the specifications
The precast covers of 1m or 3 m standard length already precast shall be placed on the
formed trench internal surface to the specified levels
The concrete shall be coloured to the specification requirement
Civil Contractor QC inspection shall be conducted followed by EPC Contractor approval
Option
If so required and felt convenient for certain standard equal depth reaches, precast concrete
members of 100 mm thick sections may be utilised to substitute 150 mm thick walls directly
resting on the prepared formation
Equipment
Excavator
Dumper truck
Compactor
Attachment
None
#87


Electrical & instrumentation
trenches
Top
Index
Scope
Reference documents
Definitions
Responsibilities
Safety
Method
Equipment
Attachment
Scope
This statement is aimed to present the procedures to be adopted to carry out the construction
of the Electrical and Instrumentation Trenches to the typical details.
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              239 of



References
Drg Paving & Under Ground services
Electrical and Instrumentation Trench and Duct Bank details
Specifications
Definitions
PSM           Project Site Manager
CSM           Construction Manager
CS            Construction Superintendent
SE            Site Engineer
FM            Foreman
QC            Quality Control
Responsibilities
PSM shall control the overall operations
CM shall arrange the resources required accordingly
CS shall control, monitor and direct the SE, FM and workforce for the operations
SE shall be responsible for all the site operations and follow the instructions of the CS
FM shall execute the operations deploying the workforce. FM shall explain in full in the
language the work persons understand about all the instruction and the ToolBox talks every
day and check that the same are followed up regularly
QC shall inspect all the operations according to the specifications
Safety
Prior to the commencement of work, the labour force shall receive a STARRT card / Toolbox
talk relevant to the operation concerned to the Project Site Safety requirements.
Any process involving a particular Safety risk shall be assessed to the requirement for Site
conditions and be taken care of.
The personnel shall use the PPE, gloves, masks (for gas leak in area), eyeglasses (during
dusty winds) etc
A safety inspector shall visit the site every day and instruct the supervisor in case any snag is
observed who immediately implement the instructions accordingly.
Materials
Mass Concrete for strip foundation beam, Concrete blocks, Precast trench covers,
oil resistant joint sealant
Method
GENERAL
Dummy / walled trench section (Detail 5 on the reference drawing)
The following operational sequences in brief are involved
Setting out to the exact alignment the route of the trench to the specified co-ordinates
Barricading the involved area to the safety department direction and requirement
Excavating the trench to the specified levels and sectional details
Preparing the formation to the required levels and dimensions
Form work for the sides of the mass concrete strip beams
Pouring the mass concrete to the strip beam forms
Setting out the alignment for the trench block walls
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              240 of



Block work 150mm thick in walls to the specified levels upto the pavement downstand beam
soffit level
Preparation and concreting the pavement portion monolithic with the downstand beam
extended upto the top of the block wall
Backfilling the trench with the excavated earth to the specifications
Placing the precast coloured concrete covers in 1m or 3m standard lengths on the relevant
compacted area
Sealing the joint between the pavement and the trench cover
Details about the above operations in general
The surveyor shall set out the alignment of the trench concerned according to the relevant
details given on the paving and underground services location plans to the reference
Co-ordinates
Civil Contractor QC shall conduct the inspection
The safety arrangement shall be discussed with the safety department and implemented
accordingly to control the trench excavation, to provide barricades, night-lights, to divert the
traffic if so required, and to adopt any other necessary measure.
The excavation shall be carried out by an excavator to the lines and the levels.
The surveyor shall monitor all stages of excavation to achieve the required profile
The excavated material shall be transported immediately by a dump truck to the earth
stockpiles temporarily
After the excavation is over, the formation levels shall be well dressed and compacted to the
specification requirement
The forms shall be fabricated for the mass concrete section
The fabricated forms of width 350mm and depth 100 mm shall be erected / fixed on the
prepared compacted formation duly aligned and levelled
Civil Contractor QC shall conduct the inspection throughout the stages of construction
The mass concrete shall be poured to the marked levels and tamped by wooden float
The forms shall be struck after the specified period
The curing of the mass concrete shall be carried out according to approved procedures and for
the specified period
The alignment of the block walls 150 mm thick shall be set out and the block work carried out
in courses in a straight line and plumb
The whole number of courses shall be laid. The fractional block course if so remained to make
up the required wall height, shall be constructed as a part of the pavement down beam
concrete by extending the bottom to the top of the block walls
The pavement / down beam monolithic pouring shall be carried out to the specified details
according to the procedures
Civil Contractor QC shall conduct the inspection throughout the stages of construction
The backfilling shall commence and the trench filled according to the specifications
The precast covers of 1m or 3 m standard length shall be placed on the filled trench internal
surface to the specified levels
The concrete shall be coloured to the specification requirement
Civil Contractor QC shall conduct the inspection throughout the stages of construction
Where the dummy trench runs over the duct bank (Ref drawing Detail 4, Sec A)
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              241 of



All the operations described in general shall be applicable herein as well with the following
amendments / additions to certain activities
Excavation shall be carried out to the top of the duct concrete only
The walls shall be started from the duct top level
Additionally, where the underground pipe runs X-ing the Trench, the specified pipe shall be laid
prior to the block work is commenced or openings shall be formed in the walls (Pipe laying
operation by others)
Flat width of the crossing shall be in size equal to the value given by the equation
 “Duct Bank length + 300x2 “
Where the dummy trench and the direct buried trench run parallel
(Ref Drg Detail 4,sec B)
All the operations described in general shall be applicable herein as well with the following
amendments / additions to certain activities
While constructing the buried trench, the profile of the dummy trench shall dictate the profile of
the buried trench
Sloping profile to a grade 1 in 2 shall be formed as shown on the drawing
Where the cable trench crossing with the closed drain pipe trench
(Ref drg Detail 6 sec C)
All the operations described in general shall be applicable herein as well with the following
amendments / additions to certain activities
The profile of the cable duct trench shall dictate the profile of the direct buried trench
The transition of the formations between the trenches and the crossing shall be in grade 1 in 2
as shown on the drawing
The length of the duct bank shall be equal to the value given by the equation
Width of the closed drain trench in mm + 2x100
The crossing flat width shall be the duct bank length + 2x300
A gap of 100mm shall be kept between the duct bank top and the closed drain bottom surfaces
The duct bank shall be constructed according to the details
Cable tiles under the closed drain trench shall be provided in the direct buried trench only
A joint shall be provided between the pavement and the closed drain trench wall
Where direct buried trench crossing under dummy trench
(Ref Drg Detail) Sec G & H)
All the operations described in general shall be applicable herein as well with the following
amendments / additions to certain activities
A level difference of 350mm shall be kept between the elevations of the crossing formation and
the dummy trench
The level transition shall be established by grading 1 in 2
The cables passing under the dummy trench shall be protected by cable tiles (By others)
The trench corner wall shall be constructed to the details showing the corner length on the
trench internal face 8485mm
Where trench with dummy Trench crossing under direct buried cable trench
(Ref Drg Detail 3 Sec E)
All the operations described in general shall be applicable herein as well with the following
amendments / additions to certain activities
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              242 of



The profile of the cable duct trench shall dictate the profile of the direct buried trench
The transition of the formations between the trenches and the crossing shall be in grade 1 in 2
as shown on the drawing
The length of the duct bank shall be equal to the value given by the equation
Width of the direct buried cable trench in mm + 2x100
The crossing flat width shall be the duct bank length + 2x300
A gap of 100mm shall be kept between the duct bank top and the closed drain bottom surfaces
The duct bank shall be constructed according to the details
Cable tiles under the closed drain trench shall be provided in the direct buried trench only
Where direct buried trench crossing under direct buried cable trench
 (Ref Drg Detail 7 Section D)
All the operations described in general shall be applicable herein as well with the following
amendments / additions to certain activities
A level difference 700 mm shall be kept between direct buried trench and the crossing
formation level
The crossing formation width shall be equal to the value from the equation in mm
(direct buried cable trench width + 400x2)
The transition of the formations between the trenches and the crossing shall be to grade 1 in 2
as shown on the drawing
Cable tiles shall be provided in unpaved areas and at trench crossing (By others)
Electric Trench Layout at Pumps (Ref Drg Detail 13)
All the operations described in general shall be applicable herein as well with the following
amendments / additions to certain activities
The pump base shall be constructed to the details
The trench walls shall be continued to the shape as shown
Option
If so required and felt convenient for certain uniform section reaches, precast concrete units
100 mm thick may be utilised to substitute 150 mm thick walls directly resting on the prepared
formation
Equipment
Excavator
Dumper truck
Compactor
Attachment
None
#88


Pull pits
Top
Index
Scope
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              243 of



Reference documents
Definitions
Responsibilities
Safety
Method
Equipment
Attachment
Scope
This statement is aimed to present the proposed procedures to be adopted to carry out the
construction of the Pull Pits
References
Specifications
Definitions
PSM           Project Site Manager
CSM           Construction Manager
CS            Construction Superintendent
SE            Site Engineer
FM            Foreman
QC            Quality Control
Responsibilities
PSM shall control the overall operations
CM shall arrange the resources required accordingly
CS shall control, monitor and direct the SE, FM and workforce for the operations
SE shall be responsible for all the site operations and follow the instructions of the CS
FM shall execute the operations deploying the workforce. FM shall explain in full in the
language the work persons understand about all the instruction and the ToolBox talks every
day and check that the same are followed up regularly
QC shall inspect all the operations according to the specifications
Safety
Prior to the commencement of any activity the labour force shall receive a Toolbox talk
relevant to the operation concerned on the project site safety requirements.
Any process involving a particular safety risk shall be assessed and addressed as required to
raise to a minimum standard / an acceptable mark.
All the safety precautions required to be adhered to while working on the excavations, mass
concrete, forms, rebars, concrete pouring etc all according to the acceptable standards, shall
be adopted on the operations concerned
Adequate safety shall be observed during lifting and offloading the precast concrete covers to
the relevant locations to avoid any mishap BY OBSERVING THE REGULATORY CRANE
FITNESS REQUIREMENT AND VALIDITY OF PERMIT.
Only competent personnel shall be engaged to carry out the operation
The crane and the trailer operators shall adhere to all the traffic rules while carrying out the
operations and if so required, a banksman be engaged to direct the movement
The crane shall not be operated during the inclement weather conditions with dust storms
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              244 of



Safety Supervision
A competent inspector shall visit the area daily to assess the safety measures adopted. Any
snag observed during the inspection shall be notified to the supervisor present who
immediately act to bring the safety measures to an acceptable standard
Materials
Mass Concrete of specified grade, Structural concrete of specified grade, Blocks, 16 mm dia
GI Lifting Lugs, Rebars all according to requirement
Method
The following operations are involved (Brief description) ( Details on the following page)
Operations in prcasting Yard
Form work to the details shown for Pit type 1 and 2 i.e. P1 and P2
Rebars placement to the details shown for Pit type 1 and 2 i.e. P1 and P2
Lifting lugs fixing to the details on the sketches attached
Pouring concrete & finishing by a steel float
Curing according to specified procedures
Lifting & loading by a crane to a trailer for transportation
On site operations- post laying of Cable ducts
Setting out
Excavation of the pit manually in case of the ducts are not encased in concrete
Mass concrete base on formation according to the details
Concrete protection according to specifications
Block work in walls according to specifications
Uncompacted sand fill only for pit Type 1
Compacted backfill only for pit Type 1
Placing the precast covers
300 mm deep sand backfill over the laid ducts not encased in concrete
As dug compacted backfill above to the specifications
Pre casting Area-The existing yard being used for the pre casting of manholes, catch basins
and lighting poles foundations etc. shall be employed for this purpose also
Details about operations in the pre-casting yard
The typical size of the Pit type 1 cover is 1990x500mm in plan and 200mm deep
The typical size of the Pit type 2 cover is 2990x500mm in plan and 200mm deep
According to the schedule 71 #s for type 1 and 81#s for type 2 are specified to be constructed
On an average 5 units shall be produced by pre casting every day
The forms to the exact size with the pre -formed chamfers shall be prepared and erected
The steel rebars shall be cut, bent to the required shape, placed with 75mm concrete spacers
and positioned into the forms.
The Lifting lugs as shown on the sketch shall be fixed in to the correct locations
All the supports and the dimensions shall be checked and corrected if required
Civil Contractor QC inspection shall be conducted from time to time throughout the operations
The concrete shall be poured to all the prepared units in 1 layers
The appropriate vibrator shall be used for the compaction of the concrete
After the concrete is poured in full & well compacted, the surface shall be levelled using a
wooden float followed by light steel trowel
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              245 of



Immediately after the concrete starts setting, saturated hessian shall be spread over the
finished surface covered with polythene sheet according to the specifications
The side forms shall be removed after the specified period
The vertical concrete surfaces shall be draped with the saturated hessian immediately after
striking the forms and covered with the polythene sheet according to specifications
The curing shall be continued for the specified period
Civil Contractor QC inspection shall be conducted from time to time throughout the operations
The relevant locations shall be made ready to receive the precast units by completing the
excavation, mass concrete, the horizontal concrete protection, block walls, backfill and forming
the correct alignment
The unit shall be lifted by a mobile crane, loaded gently onto a trailer and transported to the
location for offloading on to the prepared „location to receive‟ the unit
The unit shall be installed on the marked location according to the correct orientation to the
lighting layout drawing
Civil Contractor QC inspection shall be conducted from time to time throughout the operations
Details about operations on site
The area around the excavation coverage shall be barricaded to the site requirement based on
the direction of the safety incharge
The setting out shall be carried out by the surveyor to the required coordinates
Civil Contractor QC inspection shall be conducted from time to time throughout the operations
Excavation shall be carried out (manually if the ducts are not encased in concrete) to the
specified formation levels i.e. 1300 mm from the finished grade monitored by surveyor
Compaction and the tests if so required, shall be carried out accordingly
The form work for the mass concrete 500mm wide and 150mm thick shall be prepared and
erected to the settings
Civil Contractor QC inspection shall be conducted from time to time throughout the operations
Concrete shall be poured to the exact levels, finished properly and cured to the specified
procedures
Concrete protection shall be applied to the mass concrete top to the details & specifications
Block work shall be carried out in 200 mm width as shown on the drawings to the required
levels so that the cover placing level is 1050mm from the top of mass concrete including the
thickness of the levelling mortar. In case of the ducts are not laid in, opening shall be left in the
wall
Civil Contractor QC inspection shall be conducted from time to time throughout the operations
Uncompacted sand shall be filled as shown on the drawing in case of pit type 1
The remaining portion shall be backfilled and compacted to the specification requirement in
case of pit type 1
The top surface shall be well prepared, compacted and levelled to receive the precast covers
in case of pit type 1
The top of the block walls shall be given a cement mortar bearing in the form of a levelling
course about 20mm thick allowed to be fully set in prior to the precast cover is placed on



Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              246 of



The covers shall be offloaded by a crane from a trailer as transported from the precasting yard
to the relevant locations. The covers shall be properly spaced and levelled to the details
shown on the drawing
#89


Pull pits
Top
Index
Scope
Reference documents
Definitions
Responsibilities
Safety
Method
Equipment
Attachment
Scope
This statement is aimed to present the proposed procedures to be adopted to carry out the
construction of the Pull Pits
References

Specifications
Definitions
PSM           Project Site Manager
CSM           Construction Manager
CS            Construction Superintendent
SE            Site Engineer
FM            Foreman
QC            Quality Control
Responsibilities
PSM shall control the overall operations
CM shall arrange the resources required accordingly
CS shall control, monitor and direct the SE, FM and workforce for the operations
SE shall be responsible for all the site operations and follow the instructions of the CS
FM shall execute the operations deploying the work force & Instruct, through the medium of
language they understand, all safety precautions to be strictly adhered to as STARRT Card /
ToolBox talks every day and ascertain that these are followed up regularly
QC shall inspect all the operations according to the specifications
Safety
Prior to the commencement of any activity the labour force shall receive a Toolbox talk
relevant to the operation concerned on the project site safety requirements.

Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              247 of



Any process involving a particular safety risk shall be assessed and addressed to raise the
measures to a minimum standard / an acceptable mark.
The safety precautions required while working on the excavations, mass concrete, forms,
rebars, concrete pouring etc all according to the acceptable standards, shall be strictly adhered
to on the operations concerned
Adequate safety shall be observed during lifting and offloading the precast concrete covers to
the relevant locations to avoid any mishap BY OBSERVING THE REGULATORY CRANE
FITNESS REQUIREMENT AND VALIDITY OF PERMIT.
Only competent personnel shall be engaged to carry out the operation
The crane and the trailer operators shall abide by all traffic rules while carrying out the
operations and if so required, a banksman be engaged to direct the movement
The crane shall not be operated during the inclement weather conditions with dust storms
Safety Supervision
A competent inspector shall visit the area daily to assess the safety measures adopted. Any
snag observed during the inspection shall be notified to the supervisor present who must
immediately act to bring the safety measures to an acceptable standard
Materials
Mass Concrete of specified grade, Structural concrete of specified grade, Blocks,
16 mm dia GI Lifting Lugs, Rebars all according to requirement
Method
The following operations are involved
Operations in Precasting Yard
Pre casting Area
The existing yard being used for the pre casting of manholes, catch basins and lighting poles
foundations etc. shall be employed for this purpose also
Form work
The typical size of the Pit type 1 cover is 1900x500mm in plan and 200mm deep
The typical size of the Pit type 2 cover is 2900x500mm in plan and 200mm deep
According to the schedule 71x 6 #s each=426 #s Type 1 and 81x 6 #s each=486 #s
Type 2 covers are quantified to be constructed
On an average, 20 units shall be produced by pre casting every day
The wooden forms to the exact dimensions with pre -formed chamfers shall be prepared and
erected
Rebars placement
The steel rebars shall be cut, bent to the required shape, placed with 75mm concrete spacers
and positioned into the forms according to the details shown for type P1 & P2
Lifting lugs fixing
The Lifting lugs as shown on the attached sketch shall be fixed in to the correct locations
All supports and dimensions shall be checked and corrected if required
Civil Contractor QC inspection shall be conducted before pouring concrete and signatures
appended to ITPs
Pouring concrete & finishing
The concrete shall be poured into all the approved preparatory works in 1 layer by directly
delivering from the concrete truck / transit mixer through the chute
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              248 of



1 # ¾” needle vibrator shall be used to compact the concrete and 1 #
reserved standby
After the concrete is poured in full & well compacted, the surface shall be levelled using a
wooden float followed by light steel trowel
Curing
Immediately after the concrete is finished, the surface shall be covered with polythene sheet
with the edge lapped or tied down to exclude air circulation without permitting the membrane to
be in touch with concrete surface according to the specifications
After the concrete has stiffened but no longer than 2 hours, the polythene sheet shall be
removed followed by immediate covering the surface with saturated( soaked with mix quality
water ) hessian and recovered with polythene sheet to prevent evaporation from the hessian.
Throughout the curing period the hessian shall be maintained in a permanent wet condition
using mix quality water
The side forms shall be removed after the specified period of 24 to 36 hours as agreed
The vertical concrete surfaces shall be draped with the saturated hessian immediately after
striking the forms and covered with the polythene sheet held firmly in place along all edges &
kept continuously wet for duration of curing
The curing shall be continued for the specified period of 14 days
Civil Contractor QC inspection shall be conducted from time to time throughout the operations
Lifting, loading & transportation
The covers shall be lifted by a mobile crane, loaded gently onto a trailer and transported to the
area concerned to offload on to the prepared ‘location to receive’
On site operations- post laying of Cable ducts
The area around the excavation coverage shall be barricaded to the site requirement based on
the direction of the Construction Superintendent
Setting out
The setting out shall be carried out by the surveyor to the required co-ordinates
Civil Contractor QC inspection shall be conducted throughout the operation and ITP for the
survey check signed off
Excavation
Excavation shall be carried out (manually if the ducts are not encased in concrete) to the
specified formation levels i.e. 1300 mm (varying from area to area) from the finished grade
monitored by surveyor
Compaction and the tests if so required, shall be carried out accordingly
Mass concrete base
The form work for the mass concrete 500mm wide and 150mm deep shall be prepared and
erected to the settings
Civil Contractor QC inspection shall be conducted from time to time throughout the operations
and concrete pour ITPs signed off
Concrete shall be poured to the exact levels, finished properly and cured to the specified
procedures
Concrete protection
Concrete protection shall be applied to the mass concrete to the details & specifications
Block work in walls
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              249 of



200mm Block work shall be carried out as shown on the drawings to the required levels so that
the cover top level is 100mm from the finished grade / ground level.
In case the ducts are not laid in, opening shall be provided in the wall
Civil Contractor QC inspection shall be conducted from time to time throughout the operations
Uncompacted sand fill
Uncompacted sand shall be filled as shown on the drawing & in accordance with the
specifications
Compacted backfill
The remaining portion shall be backfilled and compacted to the specification requirement
The top surface shall be well prepared, compacted and levelled to receive precast covers
Placing the precast covers
The covers shall be offloaded by a crane from a trailer as transported from the precasting yard
to the relevant locations. The covers shall be properly spaced and levelled to the details
shown on the drawing
Sand fill
300mm deep sand backfill shall be carried out over the laid ducts not encased in concrete

Backfill
As dug compacted backfill shall be carried out above the sandfill to the specifications
Civil Contractor QC inspection shall be conducted from time to time throughout the operations
with the relevant ITPs signed off
Lugs Fill
The sand shall be filled in the lifting lugs recess
Concrete Protection
The exposed concrete surface is a part of pavement and therefore no protection shall be
applied
Equipment
Transit mixer, Trailor, Vibrator, Crane,
Attachment
3 # Sketch -showing the lifting lugs arrangement

#89


Pull pits
Top
Index
Scope
Reference documents
Safety
Method
Equipment
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              250 of



Attachment
Scope
This statement is aimed to present the proposed procedures to be adopted to carry out the
construction of the Pull Pits
References
Specifications
Safety
Prior to the commencement of any activity the labour force shall receive a Toolbox talk
relevant to the operation concerned on the project site safety requirements.
Any process involving a particular safety risk shall be assessed and addressed to raise the
measures to a minimum standard / an acceptable mark.
The safety precautions required while working on the excavations, mass concrete, forms,
rebars, concrete pouring etc all according to the acceptable standards, shall be strictly adhered
to on the operations concerned
Adequate safety shall be observed during lifting and offloading the precast concrete covers to
the relevant locations to avoid any mishap BY OBSERVING THE REGULATORY CRANE
FITNESS REQUIREMENT AND VALIDITY OF PERMIT.
Only competent personnel shall be engaged to carry out the operation
The crane and the trailer operators shall abide by all traffic rules while carrying out the
operations and if so required, a banksman be engaged to direct the movement
The crane shall not be operated during the inclement weather conditions with dust storms
Safety Supervision
A competent inspector shall visit the area daily to assess the safety measures adopted. Any
snag observed during the inspection shall be notified to the supervisor present who must
immediately act to bring the safety measures to an acceptable standard
Materials
Mass Concrete of specified grade, Structural concrete of specified grade, Blocks,
16 mm dia GI Lifting Lugs (Exposed portion only), Rebars all according to requirement
Method
The following operations are involved
Operations in Precasting Yard
Pre casting Area
The existing yard being used for the pre casting of manholes, catch basins and lighting poles
foundations etc. shall be employed for this purpose also
Form work
The typical size of the Pit type 1 cover is 1900x500mm in plan and 200mm deep
The typical size of the Pit type 2 cover is 2900x500mm in plan and 200mm deep
According to the schedule 71x 6 #s each=426 #s Type 1 and 81x 6 #s each=486 #s
Type 2 covers are quantified to be constructed
On an average, 20 units shall be produced by pre casting every day
The wooden forms to the exact dimensions with pre -formed chamfers shall be prepared and
erected
Rebars placement
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              251 of



The steel rebars shall be cut, bent to the required shape, placed with 75mm concrete spacers
and positioned into the forms according to the details shown for type P1 & P2
Lifting lugs fixing
The Lifting lugs as shown on the attached sketch shall be fixed in to the correct locations
All supports and dimensions shall be checked and corrected if required
Civil Contractor QC inspection shall be conducted before pouring concrete and signatures
appended to ITPs
Pouring concrete & finishing
The concrete shall be poured into all the approved preparatory works in 1 layer by directly
delivering from the concrete truck / transit mixer through the chute
1 # ¾” needle vibrator shall be used to compact the concrete and 1 #
reserved standby
After the concrete is poured in full & well compacted, the surface shall be levelled using a
wooden float followed by light steel trowel
Curing
Immediately after the concrete is finished, the surface shall be covered with polythene sheet
with the edge lapped or tied down to exclude air circulation without permitting the membrane to
be in touch with concrete surface according to the specifications
After the concrete has stiffened but no longer than 2 hours, the polythene sheet shall be
removed followed by immediate covering the surface with saturated( soaked with mix quality
water ) hessian and recovered with polythene sheet to prevent evaporation from the hessian.
Throughout the curing period the hessian shall be maintained in a permanent wet condition
using mix quality water
The side forms shall be removed after the specified period of 24 to 36 hours as agreed
The vertical concrete surfaces shall be draped with the saturated hessian immediately after
striking the forms and covered with the polythene sheet held firmly in place along all edges &
kept continuously wet for duration of curing
The curing shall be continued for the specified period of 14 days
Civil Contractor QC inspection shall be conducted from time to time throughout the operations
Lifting, loading & transportation
The covers shall be lifted by a mobile crane, loaded gently onto a trailer and transported to the
area concerned to offload on to the prepared ‘location to receive’
On site operations- post laying of Cable ducts
The area around the excavation coverage shall be barricaded to the site requirement based on
the direction of the Construction Superintendent
Setting out
The setting out shall be carried out by the surveyor to the required co-ordinates
Civil Contractor QC inspection shall be conducted throughout the operation and ITP for the
survey check signed off
Excavation
Excavation shall be carried out (manually if the ducts are not encased in concrete) to the
specified formation levels i.e. 1300 mm (varying from area to area) from the finished grade
monitored by surveyor
Compaction and the tests if so required, shall be carried out accordingly
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              252 of



Mass concrete base
The form work for the mass concrete 500mm wide and 150mm deep shall be prepared and
erected to the settings
Civil Contractor QC inspection shall be conducted from time to time throughout the operations
and concrete pour ITPs signed off
Concrete shall be poured to the exact levels, finished properly and cured to the specified
procedures
Concrete protection
Concrete protection shall be applied to the mass concrete to the details & specifications
Block work in walls
200mm Block work shall be carried out as shown on the drawings to the required levels so that
the cover top level is 100mm from the finished grade / ground level.
In case the ducts are not laid in, opening shall be provided in the wall
Civil Contractor QC inspection shall be conducted from time to time throughout the operations
Uncompacted sand fill
Uncompacted sand shall be filled as shown on the drawing & in accordance with the
specifications
Compacted backfill
The remaining portion shall be backfilled and compacted to the specification requirement
The top surface shall be well prepared, compacted and levelled to receive precast covers
Placing the precast covers
The covers shall be offloaded by a crane from a trailer as transported from the precasting yard
to the relevant locations ready with one layer 0.25mm thick polythene sheet with laps 300mm,
spread over.
The covers shall be properly spaced and levelled to the details shown on the drawing
Sand fill
300mm deep sand backfill shall be carried out over the laid ducts not encased in concrete
Backfill
As dug compacted backfill shall be carried out above the sandfill to the specifications
Civil Contractor QC inspection shall be conducted from time to time throughout the operations
with the relevant ITPs signed off
Lugs Fill
The sand shall be filled in the lifting lugs recess
Concrete Protection
The exposed concrete surface is a part of pavement and therefore no protection shall be
applied
Equipment
Transit mixer, Trailor, Vibrator, Crane,
Attachment
3 # Sketch -showing the lifting lugs arrangement


#90

Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              253 of




Road crossing to make good
Wearing course over completed
1# for 14” desalinated water
&
1# for 8”potable water
Avenue „c‟
Top
Index
Scope
Reference documents
Definitions
Responsibilities
Safety
Method including traffic management scheme
Equipment
Attachment
Scope
The statement is aimed to propose the procedures to be adopted to carry out to make good
the wearing course over the completed road crossing to facilitate the smooth traffic plying.The
pipe lines 1 # each 14” Desalinated water and 8” Potable water at locations identified on
attached drawing for this X-ing were completed to the following references
Reference documents
Specification. Excavation & Backfilling for Underground structures.
Drawing No. -Easement Systems Avenue “C”
Piping Interconnection Drawings, Avenue „C‟
Definitions
PSM           Project Site Manager
CSM           Construction Manager
CS            Construction Superintendent
SE            Site Engineer
FM            Foreman
QC            Quality Control
Responsibilities
PSM shall control the overall operations

Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              254 of



CM shall arrange the resources required accordingly and be overall responsible for the
excavation operation
CS shall control, monitor and direct the SE, FM and workforce for the operations
SE shall be responsible for all the site operations and follow the instructions of the CS
Any mishap on the excavation operation shall immediately be notified to the CS and the CM for
the immediate action if so required for any possible remedy or record or the authority review
whatsoever,the case may be
FM shall execute the operations deploying the workforce. FM shall explain in full in the
language the work persons understand about all the instruction and the ToolBox talks every
day and check that the same are followed up regularly
QC shall inspect all the operations according to the specifications
EPC Contractor shall conduct surveillance
Safety
Prior to the commencement of any activity the labour force shall receive a Toolbox talk
relevant to the operation concerned on the project site safety requirements. Any process
involving a particular safety risk shall be assessed and addressed as required to raise to a
minimum standard / an acceptable mark.
In the present case the minor debris removal / excavation has to be carried out on the
Operating Authority area, therefore all the regulated precautions shall be resorted to effect a
full safety standard.
ToolBox Talks-
While conducting ToolBox Talks, every precautionary measure to be adopted shall be
explained expressely to all the personnel and translated to the language understood by them
Only English literate Foreman shall be employed to work on the critical execution.
Excavation Work Permit- A copy of the work permit shall be posted on a mini board installed
on site to be noticeable to all the relevant persons involved on the crossing
Traffic Management-Sign boards keep up- All the personnel shall be briefed about the safe
keep up of the boards
Barricades,cones, markers and the night-lights, flood lights etc. shall be arranged as required
for a complete safety. No oil spillage shall be allowed.
The barriers shall be placed to indicate the excavation work in progress
Flagman-On both the direction, in addition to the traffic sign boards, a flagman shall be
engaged to operate full time to direct the traffic about the excavation work in progress by
waving the flag for all the vehicles passing by
Jack Hammer- The workers if engaged on operating this equipment shall use protective glass
and work in phases with pause intervals. The compressor air pressure shall be monitored from
time to time so that the hammer works smoothly. The compressor shall be place within the
barricade limits
Machine Excavation
The operators shall be explicitly explained and instructed about the requirement of the reverse
signal and sound when operating reverse. The truck driver shall also be instructed similarly.
Banksman shall be engaged while the equipment operate.
No violation of the traffic rules shall be allowed
Safety Supervision
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              255 of



A competent inspector shall inspect the trench daily to assess the safety measures adopted.
Method
The required permit to work shall be obtained from the Plant Refinery Division.
A traffic management scheme has been presented herein and shall be produced on site as
detailed on the attached sketch for this road crossing which includes, reduced speed sign,
temporary diverted roads sign, men at work sign, warning signs, informatory signs, safety
barriers, night lighting and road cleaning activities.
The traffic management scheme shall be reviewed and approved by EPC Contractor prior to
commencing the work.
The aforesaid traffic management scheme shall be implemented as described below:
TRAFFIC MANAGEMENT SCHEME ROAD CROSSING – First Street / Avenue „C‟
Drawing reference –
This completed crossing is located on the Road Avenue „C‟ between the following
Co-ordinates as shown on the referred drawing.

This is a 2-way road with a central verge and carrying 2 lanes on either way
The proposed crossing is located about 60 m from 1st street road towards North
One serving electric pole is located away from the x-ing to North
The minor irrigation / hoses are lying disconnected
Some minor trees and plants are arboricultured on the central verge.
The road shall be divided in 2 parts as shown on the sketch as lane L1 and L 2 on either side
of the carriageway.
In the first instance the work shall be carried out on part L1 diverting the traffic to the road
portion on the part L2 as shown on the sketch.
In the second instance the work shall be carried out on part L2 diverting the traffic to the road
portion on the completed road portion on the part L1 as shown on the sketch.
The directory signboards shall also be placed on the 1st street road East West on both ways to
indicate the work at the crossing
For the traffic North to South the first reduce speed for traffic diversion informatory board
depicting shall be located at 300 m from the point of the proposed crossing, the second
depicting diversion signs be located at 200 m and the third depicting men at work sign be
located at 100 m on either way in the opposite directions.
For the traffic South to North past crossing, one sign shall be placed to direct for the diversion,
to slow down and the men at work ahead
A Flagman shall be engaged full time on both the directions to guide the traffic about the
ongoing excavation operations in addition to the conventional signboards
The following activities are involved. Reference to the marked note „B‟ on the Easement
Systems Drawing
To produce the Traffic Diversion Management Scheme
To excavate mechaniclly the loose wearing portion to a depth so that a total concrete thickness
of 70 mm is poured
To have authority inspection
To pour the concrete
To reinstate the central verge to the existing state
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              256 of



Details
The Traffic Management Scheme shall be executed as explained in the foregoing and to the
traffic manual directions.
The first section of the proposed road crossing as per the attached sketch shall be marked by
the surveyor on the actual location. The debris / asphalt shall be cut using jackhammers or
grader to the require levels so that a final concrete thickness 70mm be poured
The excavated material shall be removed from the site to stockpile area.
The excavated trench shall be inspected by the authorities as required.
A concrete slab shall be cast up to the bottom of the finished asphalt level.
The traffic management system shall be removed after the road crossing has been cleaned of
any debris or obstructions.
Either side of the road shall be provided with cable markers to indicate the services
Major Equipment
Grader,Excavator,Dump trucks.Compactors.
Jack Hammer, Compressor,
Attachment
Sketch showing the traffic management scheme

#91
Road crossing to make good
Wearing course over completed
132 kv electric cable
Avenue „c‟
Top
Index
Scope
Reference documents
Definitions
Responsibilities
Safety
Method including traffic management scheme
Equipment
Attachment
Scope
This statement is aimed to propose the procedures to be adopted to carry out to make good
the wearing course over the completed road crossing to facilitate smooth traffic plying. Laying
of 132 KV electric cable at location identified on the reference drawing for this X-ing has been
completed
Reference documents
Specification. Excavation
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              257 of



Drawing No. -Easement Systems Avenue “C”
Definitions
PSM          Project Site Manager
CSM          Construction Manager
CS           Construction Superintendent
SE           Site Engineer
FM           Foreman
QC           Quality Control
Responsibilities
PSM shall control the overall operations
CM shall arrange the resources required accordingly and be overall responsible for the
excavation operation
CS shall control, monitor and direct the SE, FM and workforce for the operations
SE shall be responsible for all the site operations and follow the instructions of the CS
Any mishap on the crossing operation shall immediately be notified to the CS and the CM for
the immediate action if so required, for any possible remedy or record or the relevant authority
review whatsoever the case may be
FM shall execute the operations deploying the work force .and instruct in full in the medium of
language the work persons understand about all the required measures
and the STARRT / ToolBox talks every day and check that the same are followed up
regularly
QC shall inspect all the operations according to the specifications & ITP requirement
Safety
Prior to the commencement of any activity the labour force shall receive a
STARRT Card / Toolbox talk relevant to the operation concerned on the project site safety
requirements. Any process involving a particular safety risk shall be assessed and addressed
as required to raise to a minimum standard / an acceptable mark.
In this case the minor debris removal / excavation has to be carried out on the Operating
Authority area, therefore all the regulated precautionary measures shall be strictly adhered to
ToolBox Talks
While conducting ToolBox Talks, every precautionary measure to be adopted shall be explicitly
instructed to all personnel to abide by through the medium of language they understand
A Foreman who also understands English shall be employed to work on the critical execution.
Excavation Work Permit
A copy of the work permit shall be posted on a mini board installed on site to be noticeable to
all the relevant persons involved on the crossing
Barricades, cones, markers and the night-lights, flood lights etc. shall be arranged as required
for a complete safety.
The barriers shall be placed to indicate the excavation work in progress
Flagman-On both the direction, in addition to the traffic sign boards, a flagman shall be
engaged full time to direct the traffic about the excavation work in progress by means of flag
signal to all vehicles passing by

Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              258 of



Jack Hammer- The workers if engaged on operating this equipment shall use protective glass
and work in phases with pause intervals. The compressor air pressure shall be monitored from
time to time so that the hammer works smoothly. The compressor shall be place within the
barricade limits
Machine Excavation
The operators shall be explicitly instructed about the requirement of the reverse signal and
sound when operating reverse. The truck driver shall also be instructed similarly. Banksman
shall be engaged while the equipment operate.
No violation of the traffic rules shall be allowed
No oil spillage shall be allowed
Safety Supervision
A competent inspector shall inspect the area daily to assess the safety measures adopted.
Method
The required permit to work shall be obtained from the Plant Refinery Division.
A traffic management scheme has been presented herein and shall be produced on site as
detailed on the attached sketch for this road crossing which includes, reduced speed sign,
temporary diverted roads sign, men at work sign, warning signs, safety barriers, night lighting
and road cleaning activities.
The traffic management scheme shall be reviewed and approved by EPC Contractor prior to
commencing the work.
The aforesaid traffic management scheme shall be implemented as described below:
TRAFFIC MANAGEMENT SCHEME ROAD CROSSING – First Street / Avenue „C‟
Drawing reference –
This completed crossing is located on the Road Avenue „C‟ between the following
Co-ordinates as shown on the referred drawing.
This is a 2-lane dual carriageway road with a central verge
This crossing is located about 60 m from 1st street road towards North
One serving electric pole is located away from the crossing to North
The minor irrigation / hoses are lying disconnected
Some minor trees and plants are growing on the central verge.
The road shall be divided in 2 parts as shown on the sketch as lane L1 and L 2 on either side
of the carriageway.
In the first instance the work shall be carried out on part L1 diverting the traffic to the road
portion on the part L2 as shown on the sketch.
In the second instance the work shall be carried out on part L2 diverting the traffic to the road
portion on the completed portion on the part L1 as shown on the sketch.
The directory signboards shall also be placed on the 1 st street road East West on both ways to
indicate the work at the crossing
For the traffic North to South, the first informatory board for traffic depicting „reduce speed‟
shall be located at 300 m from the point of the proposed crossing, the second depicting
„diversion‟ signs be located at 200 m and the third depicting „men at work „sign be located at
100 m on either way in the opposite directions.
For the traffic South to North past crossing, one signboard shall be located to depict
„diversion‟, „slow down‟ and „the men at work ahead‟
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              259 of



A Flagman shall be engaged full time on both the directions to guide the traffic about the
ongoing excavation operations in addition to the conventional signboards
The following activities are involved.
The Traffic Diversion Management Scheme shall be executed as explained in the foregoing
and to the traffic manual requirement reflected on the attached sketch
The first section of the crossing shall be marked by the surveyor on the actual location.
The debris / asphalt shall be cut using jackhammers or grader to the required level so that a
final concrete thickness 70mm can be poured
The excavated material shall be removed from the site to stockpile area.
Concrete wearing slab 70mm thick shall be cast up to the finished asphalt level
These activities shall be repeated for the second section after the first is completed
The traffic management system shall be removed after the road crossing has been cleared of
all debris or obstructions.
Civil Contractor QC inspection shall be conducted to the ITP requirement
Either side of the road shall be provided with cable markers to indicate the services
In future, after the completion of the proposed pipe laying operations
(For which the methodology is included separately, ref. method statement # 86),
an approved asphalt wearing course shall be laid to the requirement to replace 70mm concrete
paving
Major Equipment
Grader,Excavator,Dump trucks.Compactors.
Jack Hammer, Compressor,
Attachment
Sketch showing the traffic management scheme
Civil Contractor QC inspection shall be conducted from time to time throughout the operations
The sand shall be filled in the lifting lugs recess
The exposed concrete surface is a part of pavement and therefore no protection shall be
applied
Equipment
Transit mixer, Trailor, Vibrator, Crane,
Attachment
4      # Sketch -showing the lifting lugs arrangement

#92

Road crossing
To make good (temporarily)
Wearing course over completed

Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              260 of




132 kv electric cable
Avenue „c‟
Top
Index
Scope
Reference documents
Safety
Method including traffic management scheme
Equipment
Attachment
Scope
This statement is aimed to propose the procedures to be adopted to carry out to make good
the wearing course over the completed road crossing to facilitate smooth traffic plying. Laying
of 132 KV electric cable at location identified on the reference drawing for this X-ing has been
completed
Reference documents
Specification. Excavation
Drawing No.
Safety
Prior to the commencement of any activity the labour force shall receive a
STARRT Card / Toolbox talk relevant to the operation concerned on the project site safety
requirements. Any process involving a particular safety risk shall be assessed and addressed
as required to raise to a minimum standard / an acceptable mark.
In this case the minor debris removal / excavation has to be carried out on the Operating
Authority area, therefore all the regulated precautionary measures shall be strictly adhered to
ToolBox Talks
While conducting ToolBox Talks, every precautionary measure to be adopted shall be explicitly
instructed to all personnel to abide by through the medium of language they understand
A Foreman who also understands English shall be employed to work on the critical execution.
Excavation Work Permit
A copy of the work permit shall be posted on a mini board installed on site to be noticeable to
all the relevant persons involved on the crossing
Barricades, cones, markers and the night-lights, flood lights etc. shall be arranged as required
for a complete safety.
The barriers shall be placed to indicate the excavation work in progress
Flagman-On both the direction, in addition to the traffic sign boards, a flagman shall be
engaged full time to direct the traffic about the excavation work in progress by means of flag
signal to all vehicles passing by
Jack Hammer- The workers if engaged on operating this equipment shall use protective glass
and work in phases with pause intervals. The compressor air pressure shall be monitored from
time to time so that the hammer works smoothly. The compressor shall be place within the
barricade limits
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              261 of



Machine Excavation
The operators shall be explicitly instructed about the requirement of the reverse signal and
sound when operating reverse. The truck driver shall also be instructed similarly. Banksman
shall be engaged while the equipment operate.
No violation of the traffic rules shall be allowed
No oil spillage shall be allowed
Safety Supervision
A competent inspector shall inspect the area daily to assess the safety measures adopted.
Method
The required permit to work shall be obtained from the Plant Refinery Division.
A traffic management scheme has been presented herein and shall be produced on site as
detailed on the attached sketch for this road crossing which includes, reduced speed sign,
temporary diverted roads sign, men at work sign, warning signs, safety barriers, night lighting
and road cleaning activities.
The traffic management scheme shall be reviewed and approved by EPC Contractor prior to
commencing the work and agreed with Plant Refinery Division.
The aforesaid traffic management scheme shall be implemented as described below:
TRAFFIC MANAGEMENT SCHEME ROAD CROSSING – First Street / Avenue C‟
This crossing is located about 83 m from center line of 1st street road towards North
The road shall be divided in 2 parts as shown on the sketch as lane L1 and L 2 on either side
of the carriageway.
In the first instance the work shall be carried out on part L1 diverting the traffic to the road
portion on the part L2 as shown on the sketch.
In the second instance the work shall be carried out on part L2 diverting the traffic to the road
portion on the completed portion on the part L1 as shown on the sketch.
Signboards shall be positioned as shown on the sketch
A Flagman shall be engaged full time on both the directions to guide the traffic about the
ongoing excavation operations in addition to the conventional signboards
The temporary stone surface on lane L1 shall be excavated to a depth of 70mm and replaced
by mass concrete to level with the adjacent asphalt.
Traffic shall be allowed on to the concrete after 2 days and the operation shall be repeated for
lanes L2
All excavated material shall be removed to an approved tipping area.
The concrete surface shall be replaced by asphalt to the same specification as the existing
construction at the earliest opportunity
Major Equipment
Grader,Excavator,Dump trucks.Compactors.
Jack Hammer, Compressor,
Attachment
Sketch showing the traffic management scheme

#93

Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              262 of




Drinking water connection
Top
Index
Scope
Reference documents
Definitions
Responsibilities
Safety
Method
Equipment
Attachment
Scope
The purpose of this method statement, is to define the procedure that shall be adopted for the
connection and laying of the pipeline, from the Operating Authority supply pit No 21, to the Civil
Contractor camp.
Reference documents
Excavation permit.
Definitions
Operating Authority Abu Dhabi National Oil Company.
EPC Contractor
Civil Contractor     .
PSM        Project Site Manager.
Responsibilities
The Civil Contractor PSM shall ensure this method statement is implementation for the
connection and laying of the drinking water pipeline.
Safety
The Safety Officer shall monitor the daily activities, advising and implementing all safety
procedures.
Method
The proposed drinking water connection location and route of the pipeline, shall be defined
upon a drawing, which shall be reviewed and approved by Operating Authority.
The approved pipeline route drawing shall define the materials and fitting locations.
All trenching activities shall be excavated by hand. The excavated material shall be stockpiled
for re-use as fill material. The pipe trench shall be excavated to a depth of 500mm.
All stones and hard materials from the bottom of the trench shall be removed. The pipe shall
be located within the trench. Selected backfill shall be placed around the pipe.
The trench shall be backfilled with the excavated material. Any surplus material shall be
removed from site.
The laying and connection of the pipes shall be conducted by experienced people.
Where the pipeline passes beneath a roadway, a sleeve pipe shall be incorporated to protect
the water pipe from damage.
Testing of the pipes shall be conducted to ensure that leakage does not occur.
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              263 of



Marker posts to indicate a buried service shall be installed upon completion of backfilling and
clearing of the site.
Equipment
Hand tools.
Pipe jointing and cutting tools.
Attachment
Work permit.
Drawing Site Sketch
#94
Protection to transformer foundation sides in
sub stations
with aluminium bead termination for below ground and
masterseal 300h for above ground in gravel fill area
Top
Index
Scope
Reference documents
Definitions
Responsibilities
Safety
Method
Equipment
Attachment
Scope
This statement is aimed to propose the procedures to be adopted to protect the vertical
surfaces of the transformer bases concrete using Aluminium Beads to clampin the
waterproofing membrane termination around the foundation sides and apply concrete
protection coating on the surfaces above ground
References
Main Substation Drawing Transformer Foundations Sec A & D and the relevant drawings for
all other sub stations
Specifications-
Definitions
PSM            Project Site Manager
CSM            Construction Manager
CS             Construction Superintendent
SE             Site Engineer
FM             Foreman
QC             Quality Control

Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              264 of




Responsibilities
PSM shall control the overall operations
CM shall arrange the resources required accordingly
CS shall control, monitor and direct the SE, FM and workforce for the operations
SE shall be responsible for all the site operations and follow the instructions of the CS
FM shall execute the operations deploying the workforce. FM shall explain in full in the
language the work persons understand about all the instruction and the toolbox talks every day
and check that the same are followed up regularly
QC shall inspect all the operations according to the specifications
EPC Contractor shall conduct surveillance
Safety
Prior to the commencement of work, the labour force shall receive a toolbox talk on the Project
Site Safety requirements relevant to the application of below ground and above ground
concrete surface protection operations

Any process which may involve a particular Safety risk shall be assessed to the requirement
for Site conditions and be taken care of.
The personnel shall use the PPE, gloves, masks, eyeglasses etc.
Care shall be taken during use and storage to avoid contact with eyes, mouth, skin and
foodstuffs.
To avoid skin contact, use of barrier cream to protect from the adverse effect of sealant and
other chemicals application shall also be made.
Industrial cleaner shall be used followed by washing with soap and water.
The containers shall be resealed after use.
Immediate medical attention shall be called for in case of any adverse effect to the personnel
handling the product
Damaged tins shall be disposed off according to the state regulations.
Material safety data shall also be referred to for disposal and any further information.
A safety inspector shall visit the site every day and instruct the supervisor in case any snag is
observed who immediately implement the instructions accordingly.
Materials
Bitustick XL Polybit MAR 003
Aluminium Bead lengths to the Sectional dimensions 30 mm x 2 mm
Fixing screws 3 mm dia
Joint filler Alpex Joint Fill BCR MAR 008
Sealant- Polyurethane-Gun Grade Cold seal 200PF for horizontal usage on Aluminium strip
(Manufacturer BCR) (Emirates Specialities) or equivalent MAR
Masterseal 300H MBT MAR 059
Masterseal 181S Primer system
Masterseal 300H filler
Storage
The manufacturer‟s instructions shall be followed for this purpose.

Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              265 of



The material shall be stored under cover out of direct sunlight and protected from temperature
extremes.

Method
Waterproofing membrane shall be applied according to the specifications to the defined levels
keeping the top 50 mm above the gravel fill
Marking shall be made to the exact line and level as per drawing
Required lengths to the exact site dimensions shall be cut to suit a close fit between the bead
ends
Every bead shall be fixed with screws @ 400mm centres drilled and tightened to the concrete
penetrating the membrane
The screws shall be drilled and fixed using an electrical operated equipment
After the screws are drilled in with the beads in proper alignment / location, compressed fibre
shall be installed as protection over the Bitustick XL membrane as specified
Civil Contractor QC inspection shall be conducted followed by EPC Contractor approval
The vertical surface above the bead as well as a 50mm wide strip around the top periphery of
the foundation shall be prepared for the above ground concrete protection and Master seal 300
H be applied to the manufacturer‟s instructions
This application involves the following sequences
Cleaning and making up the surface
Priming the surface
Coating the surface
Preparation
All surfaces shall be free from oil, grease, friable matters and curing compound.
The surfaces shall be cleaned from dust / sand using compressed air.
Arrises shall be rounded off and the protrusions ground so that the resulting surfaces appear
smooth.
The surfaces shall be brush primed with Masterkure 181S and subsequently Masterseal 300H
mixed with Masterseal 300 H filler applied as a scrape coat over blow holes and depressions.
The primed surface shall be allowed to dry tack free for a minimum duration of 2 hours before
applying Masterseal 300H coating.
Application
The areas to be coated shall be protected from direct sunlight by shading in the hot weather
conditions.
At the time of coating application the ambient temperature shall be more than 5 degree
Celsius with humidity less than 90 % and no dusty weather
Masterseal 300 H shall be applied directly from the containers using a brush or roller @ 0.8
litre per sqm surface coverage to achieve a continuous coating
The continuous coating shall be achieved in 1 or 2 coats of application
The coating shall be protected from the humidity for 24 hours / or until it dries out using
polythene sheets keeping off the area.
No post application curing is required

Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              266 of




Civil Contractor QC inspection shall be conducted followed by EPC
Contractor approval
Application of sealant after 24 hours
The material shall be applied using a sealant gun fitted with conical nozzles adjustable to suit
the width
The sealant shall be gunned into the junction using an even trigger pressure,
The nozzle shall be cleaned occasionally to avoid contamination.
A smaller timber spatula soaked in soapy water shall be used to compact the sealant into the
joint for a smooth polish finish formation.
The mixing and application equipment shall be cleaned immediately after use
Civil Contractor QC inspection shall be conducted followed by EPC Contractor approval
Equipment
Electrical operated drill
Sealant applying gun
Brush and roller
Attachment
None
#95

Timber doors fixing
Administration building
Top
Index
Scope
Reference documents
Definitions
Responsibilities
Safety
Method
Equipment
Attachment
Scope
This statement is aimed to present the proposed procedures to be adopted to carry out the
fixing of the workshop / factory builtin wooden doors to the exact locations on the prepared
openings left in the walls




Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              267 of




References
Specifications
MAR
Teak Wood
Definitions
PSM                      Project Site Manager
CSM                      Construction Manager
CS                       Construction Superintendent
SE                       Site Engineer
FM                       Foreman
QC                       Quality Control
Responsibilities
PSM shall control the overall operations
CM shall arrange the resources required accordingly
CS shall control, monitor and direct the SE, FM and workforce for the operations
SE shall be responsible for all the site operations and follow the instructions of the CS
FM shall execute the operations deploying the workforce. FM shall explain in full in the
language the work persons understand about all the instruction and the ToolBox talks every
day and check that the same are followed up regularly
QC shall inspect all the operations according to the specifications
EPC Contractor shall conduct surveillance
Safety
Prior to the commencement of work, the labour force shall receive a Toolbox talk relevant to
the operation concerned to the Project Site Safety requirements.
Any process that is adopted which may have a particular Safety risk shall be assessed to the
requirement for Site conditions and be taken care of.
The personnel shall use the PPE, gloves, masks (for gas leak in area), eyeglasses (during
dusty winds) etc
Adequate arrangement shall be made to provide access to the top of the wall.
A safety inspector shall visit the site every day and instruct the supervisor in case any snag is
observed who immediately implement the instructions accordingly.
Materials
Material from Aldiar UAE
1 hour fire rated, ½ hour fire rated
Method
The following operations are involved
Equipment
Attachment
None
#96

Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              268 of




Grouting to steel tanks bearings on
ring beams
Top
Index
Scope
Reference documents
Definitions
Responsibilities
Safety
Method
Equipment
Scope
The statement is aimed to propose the procedures to be adopted to grout the space between
the top of the ring beams and the steel tank base plate(acting as bearing) according to the
following drawings and the specifications.
Reference Documents.
Drgs Demineralised Water Tank
Drgs Spent Caustic Storage Tank
Drgs Fire Water Storage Tank
Drgs Fire Water Storage Tank
Drgs Caustic Storage Tank
Drgs Neutralisation Tank Water Tank
Specification
Definitions
PSM           Project Site Manager
CSM           Construction Manager
CS            Construction Superintendent
SE            Site Engineer
FM            Foreman
QC            Quality Control
Responsibilities
PSM shall control the overall operations
CM shall arrange the resources required accordingly
CS shall control, monitor and direct the SE, FM and workforce for the operations
SE shall be responsible for all the site operations and follow the instructions of the CS
FM shall execute the operations deploying the workforce. FM shall explain in full in the
language the work persons understand about all the instruction and the toolbox talks every day
and check that the same are followed up regularly
QC shall inspect all the operations according to the specifications


Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              269 of




Safety
Prior to the commencement of work, the labour force shall receive a STARRT Card / Toolbox
talk on the Project Site Safety requirements relevant to the application of Masterflow 928T
MBT grouthing material according to the manufacturer‟ s instruction and the filling the sand into
minutely narrow spaces
The personnel shall use the PPE, gloves, masks, eyeglasses etc.
Care shall be taken during use and storage to avoid contact with eyes, mouth, skin and
foodstuffs.
To avoid skin contact, use of barrier cream to protect from the adverse effect of grouting
material shall also be made.
Industrial cleaner shall be used followed by washing with soap and water.
The containers shall be resealed after use.
Immediate medical attention shall be called for in case of any adverse effect to the personnel
handling the product
Material safety data shall be referred to for disposal and any further information.
A safety inspector shall visit the site every day and instruct the supervisor in case any snag is
observed who immediately implement the instructions accordingly.
Method
Refer to the sketch attached
The space to be grouted shall be cleaned to remove all dirt and loose particles using
compressed air
The surrounding area shall be shaded to avoid the effects of temperature extremes
The grouting operation shall be carried out in pieces on the tank circumference
The surface shall be soaked in water for 24 hours prior to conmmence the operations
Sandfilling shall be carried out into the spaces leaving a clear portion 200 mm wide for the
grouting purpose. A backing rod 25 mm dia shall be provided as shown on the sketch
The space to be filled in various locations shall be prepared by form strips of the size equal to
the thickness of the grout circumferentially and radially. The pouring end shall be kept open
and after the pouring is completed in the prepared area, shall be closed
An electric drill fitted with a paddle mixer shall be used for the grout mixing purpose. The mixer
shall be cleaned with no standing water.
Using water @ 3.5 to 4.5 litres per 25 kg bag of Master flow 928T according to the
requirement, the mixing shall be carried out as follows
90 % of the measured quantity of water required to achieve the desired consistency according
to the batch volume shall be added to the mixer followed by the grout material Masterflow
928 T added gradually.The remaining 10 % water quantity shall be poued during mixing, which
has to be kept continued for at least 3 to 5 minutes until a uniform lump free consistency is
achieved.
Civil Contractor QC inspection shall be conducted according to the ITP requirement
The grout shall be poured continuously using the pour cone with a constant hydrostatic head
of at least 15 cm
Civil Contractor QC inspection shall be conducted according to the ITP requirement

Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              270 of



After pouring the grout Masterflow 928 in place, all the exposed surfaces shall be covered
with clean and damp Hessian to keep the applied material moist until it is firm enough to
accept a curing membrane
The specified temperature range(4 to 32 degree C) shall be maintained for the 3 post pour
continuous days
The grout thickness varies between 25 to 35 mm.
Major Equipment
Peddle Mixer
Grout Flow Cone
Attachment
Sketch
#97

Grouting to steel tanks bearings on
ring beams
Top
Index
Scope
Reference documents
Safety
Method
Equipment
Scope
The statement is aimed to propose the procedures to be adopted to grout the space between
the top of the ring beams and the steel tank base plate(acting as bearing) according to the
following drawings and the specifications.
Reference Documents.
Drgs Demineralised Water Tank
Drgs Spent Caustic Storage Tank
Drgs Fire Water Storage Tank
Drgs E Fire Water Storage Tank
Drgs Caustic Storage Tank
Drgs Neutralisation Tank Water Tank
Specification
Safety
Prior to the commencement of work, the labour force shall receive a STARRT Card / Toolbox
talk on the Project Site Safety requirements relevant to the application of Masterflow 928T
MBT grouting material according to the manufacturer‟ s instruction and the filling the sand into
minutely narrow spaces
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              271 of



The personnel shall use the PPE, gloves, masks, eyeprotection etc.
Care shall be taken during use and storage to avoid contact with eyes, mouth, skin and
foodstuffs.
To avoid skin contact, use of barrier cream to protect from the adverse effect of grouting
material shall also be made.
Industrial cleaner shall be used followed by washing with soap and water where grout comes
in contact with skin.
Immediate medical attention shall be called for in case of any adverse effect to the personnel
handling the product
Material safety data shall be referred to for disposal and any further information.
A safety inspector shall visit the site every day and instruct the supervisor in case any snag is
observed who immediately implement the instructions accordingly.
Method
Refer to the sketch attached
The space to be grouted shall be cleaned to remove all dirt and loose particles using
compressed air
The surrounding area shall be shaded to avoid the effects of temperature extremes
The grouting operation shall be carried out in pieces on the tank circumference
The surface shall be soaked in water for 24 hours prior to conmmence the operations
Sandfilling shall be carried out into the spaces leaving a clear portion 200 mm wide for the
grouting purpose. A backing rod 25 mm dia shall be provided as shown on the sketch
The space to be filled in various locations shall be prepared by form strips of the size equal to
the thickness of the grout circumferentially and radially. The pouring end shall be kept open
and after the pouring is completed in the prepared area, shall be closed
An electric drill fitted with a paddle mixer shall be used for the grout mixing purpose. The mixer
shall be clean with no standing water.
Using water @ 3.5 to 4.5 litres per 25 kg bag of Master flow 928T according to the
requirement, the mixing shall be carried out as follows
90 % of the measured quantity of water required to achieve the desired consistency according
to the batch volume shall be added to the mixer followed by the grout material Masterflow
928 T added gradually.The remaining 10 % water quantity shall be poued during mixing, which
has to be kept continued for at least 3 to 5 minutes until a uniform lump free consistency is
achieved.
Civil Contractor QC inspection shall be conducted according to the ITP requirement
The grout shall be poured continuously using the pour cone with a constant hydrostatic head
of at least 15 cm
Civil Contractor QC inspection shall be conducted according to the ITP requirement
After pouring the grout Masterflow 928 in place, all the exposed surfaces shall be covered
with clean and damp Hessian to keep the applied material moist until it is firm enough to
accept a curing membrane
The grout thickness varies between 25 to 35 mm.
Major Equipment
Paddle Mixer
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              272 of



Grout Flow Cone
Attachment
Sketch

#98

Excavation                                                      for                      ccb                         underground
water tank
Top
Index
Scope
Reference documents
Definitions
Responsibilities
Safety
Method
Equipment
Scope
The statement is aimed to propose the procedures to be adopted to excavate the area for the
underground water tank foundation where one cable trench is passing 1400 mm apart from
one of the longitudnal (East) walls
Reference Documents.
Drgs Underground WaterTank Structural Details
Specification
Definitions
PSM           Project Site Manager
CSM           Construction Manager
CS            Construction Superintendent
SE            Site Engineer
FM            Foreman
QC            Quality Control
Responsibilities
PSM shall control the overall operations
CM shall arrange the resources required accordingly
CS shall control, monitor and direct the SE, FM and workforce for the operations
SE shall be responsible for all the site operations and follow the instructions of the CS
FM shall execute the operations deploying the workforce. FM shall explain in full in the
language the work persons understand about all the instruction and the toolbox talks every day
and check that the same are followed up regularly
QC shall inspect all the operations according to the specifications

Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              273 of




Safety
Prior to the commencement of work, the labour force shall receive a STARRT Card                 /
Toolbox talk on the Project Site Safety requirements relevant to the deep excavation.
Required safety arrangements shall be made by installing barricades and night lights
A safety inspector shall visit the site every day and instruct the supervisor in case any snag is
observed, who immediately implement the instructions accordingly to get the measures to an
acceptable standard
Method
Refer to the sketch attached
The setting out of the tank area shall be carried out to the relevant co-ordinates
Civil Contractor QC inspection shall be conducted to the ITP requirement
Safety barricades shall be provided according to the requirment
Since the work is also in progress on the chiller area, the access to the formation shall be
provided from the two shorter sides by benching
The location of the longitudnal walls shall be marked adding 50 mm margin for the
backblinding
Longitudnally the excavation line shall be kept to vertical profile that is feasible for the soil is
sufficiently stiff
Necessary forms shall be erected in stages for the vertical / back blinding and the concrete
poured to form a soil protective surface
After the blinding is over, further activities of the tank construction shall be followed according
to the relevant drawings and the specifications
Major Equipment
Excavator
Truck
Attachment
Sketch
#99

Excavation                                                      for                      ccb                         underground
water tank
Top

Index
Scope
Reference documents
Safety
Method
Equipment
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              274 of




Scope
The statement is aimed to propose the procedures to be adopted to excavate the area for the
underground water tank foundation where one cable trench is passing 1400 mm apart from
one of the longitudnal (East) walls
Reference Documents.
Drgs Underground WaterTank Structural Details
Specification
Safety
Prior to the commencement of work, the labour force shall receive a STARRT Card / Toolbox
talk on the Project Site Safety requirements relevant to the deep excavation.
Required safety arrangements shall be made by installing barricades and night lights
A safety inspector shall visit the site every day and instruct the supervisor in case any snag is
observed, who immediately implement the instructions accordingly to get the measures to an
acceptable standard
Method
Refer to the sketch attached
The setting out of the tank area shall be carried out to the relevant co-ordinates
Civil Contractor QC inspection shall be conducted to check the coordinates
Safety barricades shall be provided according to the requirment
The location of the longitudnal walls shall be marked & the excavation lines demarcated
according to the sketch attached
Excavation shall commence from the free side and continued to the cable trench line following
the section shown on the sketch
The existing soil is stiff enough to be excavated to a vertical profile but tempararily,on the cable
trench side pre cast concrete cubes 1mx1mx1m shall be used to retain the earth pressure as
shown on the sketch
After the cubes are placed in, further construction operations shall be carried out to the
drawings and specifications
Cubes shall be used to act as a support to the forms
After the cubes placement, further activities of the tank construction shall be followed
according to the relevant drawings and the specifications
Major Equipment
Excavator
Truck
Attachment
Sketch

#99

Soakaway chambers
Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches
have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for
acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents.
A work based on personal experience                 Engineering Construction Method Statements                                                Revision No: Original Work by
for improving young engineers /                                                                                                               P Eng Suraj Singh April 11, 2006 Page
students knowledge
                                                                                                                                              275 of




Top
Index
Scope
Reference documents
Safety
Method
Equipment
Attachment
Scope
The statement is aimed to propose the procedures to be adopted to carry out the construction
of soakaway chambers
Reference documents
Drawing No
Specification
Safety
Prior