1. PURPOSE The purpose of this Method Statement is to provide General Guidelines for Cable laying & Cable Termination Termination for the Project PE # ! " Poer$ Control & Signal Cables for The Scrap Pellet recovery project for %bu habi Polymer Company 'td( )*+,+-GE. at the ,uais /ndustrial %rea$ %bu habi Emirate( 2. SCOPE Scope of this Method Statement covers the folloing activities( Material 0andling Procedure Precautions Testing Testing /nspections •
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3. REFE REFERE RENC NCES ES The 1olloing documents & draings are considered considered for reference documents" Project Speci2c Cable ,oute draings( {please indicate specifc drawing reerences} Project Speci2cations Project 3uality Plan )P3P. /nspection & Test Plan)/TP. •
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4. DEFI DEFINI NITI TION ONS S +45E," +45E," %bu habi Polymer Company ltd( 6*+,+-GE7 E5G/5EE," {please indicate Consultant/Engineer’s name.} C+5T,%CT+," C+5T,%CT+," %l 0usam General Contracting Est( %8 %8" % consecutive consecu tive calendar calend ar day unless otherise other ise stated M%8" /s used here a provision is discretionary discretion ary P'%5T" P'%5T" Machinery$ computer hardare and softare$ apparatus$ materials$ articles and things of all 9ind to be provided under the contract other than Contractor:s E;uipment( P,+
MANPOWER
5.1.1 5.1.1 PROJE PROJECT CT MANAG MANAGER ER : The Project Manager has the overall administrative responsibility responsibility for the implementation of this method statement( Coordinates the or9s ith the Site Manager to ensure they are carried out according to the planned program( •
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Conveys to the Site Manager the importance of adhering to all safety measures and ;uality control in co?ordination ith Safety Engineer and 3C Engineer and in line ith the 0SE Plan and 3uality Plan(
5.1.2 Site Maa!e" : •
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The Site Manager has the overall site responsibility for the implementation of this method statement( Ensures that approvals from all concerned authorities has already been obtained before proceeding ith trial pit e@cavation and made available to his site team( Ensures that the or9s are carried out according to the planned program and that all the e;uipment re;uired to e@ecute the or9s shall be available as per the project planning and are in good condition( Coordinates ith the Project Engineer = Site Engineer$ Safety Engineer$ 3uality Control Engineer and for the orderly$ safe and proper e@ecution of the or9( Speci2c attention shall be given to all safety measures and ;uality control in co?ordination ith Safety Engineer and 3C Engineer and in line ith the 0SE Plan and 3uality Plan(
5.1.3 P"#$e%t E!iee" Site E!iee": Ensures that all the or9s are to be carried out according to the speci2cations and approved shop draings( Provides all necessary information and assigns the responsibilities to his construction team( Ensures and monitors the or9 progress of or9 in accordance ith the re;uired program and report the same to the Project Manager( Coordinates ith the Safety Engineer to ensure that the or9s are carried out in a safe or9ing practice( Coordinates ith the 3%=3C Engineer for the tests )if any. to be carried out and initiates for the inspection for the or9 activities( Ensures the implementation of any re;uest that might be raised by the Consultant( Coordinates ith the site foreman and plans the or9s in advance as per the or9 se;uence( •
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5.1.4 S'"(e)#": Shall ensure that 5e %bu habi atum reference survey points=mar9ers are obtained and located at or near the or9 site( Shall ensure that all coordinates values are in 4GS A?-TM$ Bone !5 Coordinate System( Shall ensure that e@isting buried services are already located$ identi2ed and e@posed prior to e@cavation( Shall supervise the chec9ing of trench depth and grade )as may be re;uired. during e@cavation( •
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5.1.5 *SE E!iee"O+%e":
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Ensures the implementation of all Safety measures in accordance ith the 0SE plan and ensures that everybody is fully aare of it for safe or9 implementation( Ensures all the implemented safety measures are ade;uate to m aintain the safe or9ing environment on site( /nspects all the site activities and trains the persons to prevent incidents and avoid accidents and to properly report any incidents and accidents to the Project Manager and Consultant( Ensures that the site is maintained clean$ tidy and free of obstacles that could endanger safety(
5.1., QAQC E!iee": Ensures that all the re;uired permits and clearance are already obtained and still valid before starting the or9( Maintains inspection and test records complete for any future reference. •
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5.1.- Ote" Pe"/#e0 "e'i"eet:
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Technicians 0elpers *an9s men 1or9 lift operator Crane +perator
4hose responsibilities include 1ollo Safety ,ules & ,egulations ,eport any haard in or9 place ,eport any accident or near miss /dentify ris9s in or9place and associated haards The usage of issued PPE ,eport any defects in machinery and e;uipment ,eport any non?conformance identi2ed at or9 site • • • • • • •
5.2 E'iet T##0/ {Please add or delete equipment according to site requirement} a.
Transportation vehicle
9. Portable 'ights l.
o. %C 0igh oltage Test Hit = '1 Test Hit p. Manual E@cavation Tools ;. ,emovable *arricades
,. PROCEDURE ,.1 ECAATION & 6AC7FI88ING ,.1.1PREPERATION & PRECONDITIONS a. Permit to 4or9 )PT4. if re;uired shall be raised to the +ner=Engineer for the e@cavation clearly mentioning the location of or9$ sie of e@cavation and levels( b. E@cavations area shall be surveyed and mar9ed to the lines and levels as shon on the draings( c. The area of e@cavation ill be cordoned oI using safety barricading to stop trespassers( d. %ssign suJcient ban9s men$ helpers and supervisors at the site prior to start of e@cavation( e. ,e;uired sign boards such as 6EEP EKC%%T/+57 6ME5 4+,H/5G7$ 6%5GE,7 and arning boards ill be placed to indicate the e@cavation or9( f. Ensure the or9ing area at any con2ned space is free from any 0aardous Gas by proper Gas testing using the Gas testing instrument( g. /f there are structures adjacent to the or9 area$ proper temporary supports shall be provided to the adjacent structure prior to start e@cavation( h. 1ences and minor structures of any character or upon ithin the limits of the or9s and not necessary for the construction shall be removed carefully and stored neatly for reinstating after the construction or9s( i. /f any Survey points$ bench mar9s$ boundary stones and mar9ings falling on the area shall be removed only ith the +45E, = E5G/5EE,Ls ritten consent and shall be stored and reinstated according to +45E, = E5G/5EE,Ls instructions( j. Chec9 the area of e@cavation to 2nd out any underground facilities other than listed in topographical survey by" -sing appropriate detective e;uipment$ such as cable detector$ metal detector etc( Chec9 e@isting e@posed e@cavation nearby area to 2nd out e@isting underground facilities( ,efer available %s?built draings from the Company$ other agencies$ other contractors doing projects nearby areas and mar9 in the area( Ta9e trial= test pits to 2nd out e@isting underground pipes$ structures( Chec9 the indication mar9s$ signs$ manholes nearby area and 2nd out the path of services( •
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ECAATION
,.2.1 T"ia0 Pit a9 E%a(ati# P"#%e9'"e/
a. Prior to star of any e@cavation$ the area shall be chec9ed for the e@isting services= utilities by obtaining the approvals ith reference to the relevant draings( b. The necessary e@cavation activities shall start only after getting the notice intent from the Concerned %uthorities ho have services =installation in the vicinity or plan to install their services in the general area in the near future( c. E@cavation of the trial pits shall be done manually as per the sie indicated in the approved draings up to the re;uired length and level( d. /n open areas the e@cavation shall be carried out by using the machineries$ the e@act location of each trench and pit being subjected to the prior approvals( e. Manual e@cavation ill be carried out to e@pose the e@isting utilities$ if any$ hich has to be identi2ed( f. The trenches shall be 9ept dry during cable installation operation( The contractor shall deal ith the dispose of ater so as to prevent any ris9 to the cables and other materials( g. The contractor shall provide suitable deatering hile performing the or9s according to the scope of or9( h. The re;uired control measures shall be developed and implemented hile performing the or9s and more importance ill be given for public safety and environmental issues( i. 4hile performing the or9 the trenches shall be straight$ free from any sharp objects=edges li9ely to injure the cable or accessories and 2lled ith soft sand and sieved sand to form smooth bedding before the cables are laid( j. The contractor shall ta9e the necessary precautions to prevent damage to the road or ground surface due to a slip or brea9ing aay from the side alls of the trench including the pedestrian safety as ell( 9. The vehicle entry shall be restricted on the speci2ed or9 area by prior approval from the concerned agencies( l. 4here ever there is a crossover of the e@isting services=utilities$ these shall be protected ith utmost care ith the prior permission of concerned authorities and approved methods( m. /n case of other projects in the same vicinity$ the contractor shall obtain the necessary approval from the +ner=Engineer & the Engineer for the concerned project to clarify the scope of the or9s and boundaries of the other project$ according to the scope of the or9( n. E@cavate the area by using only hand tools as per the mar9ings and levels ith proper protection of sides o. The bottom of the e@cavation shall be levelled and trimmed to receive the permanent or9s( p. Provide proper rigid barriers around e@cavations include provision of ladders$ emergency escape ay$ ade;uate side slopes or shoring and shuttering$ detours(
,.2.2 ECAATION ADJACENT TO UNDERGROUND SERICES a. E@cavation near the e@isting electrical cables$ instrumentation and control cables$ seer line$ gas lines and any other service line shall ta9e all necessary precautions to protect the services ith proper supports & covers(
b. %ll e@isting structures$ foundations$ pipes and cables$ if any$ hich are to be incorporated into the 2nal or9$ shall be ade;uately protected from damage( c. %ll underground services located during e@cavation shall be mapped for consideration during construction of the or9s( d. /f any underground service is noticed other than speci2ed in the area during e@cavation shall be brought in notice of the +45E, e. E@cavation shall not be carried out adjacent to or near e@isting building foundations$ ithout suitable shoring=sheet piling(
,.3 6AC7FI88ING ,.3.1Gee"a0 a. *ac92lling area shall be bac92lled ith approved material compacted in layers by suitable e;uipment li9e plate compactors$ vibratory roller compactors$ etc($ until the speci2ed density has been obtained to the satisfaction of the +45E,= E5G/5EE,( b. Compacting shall be carried out ith special care by means of mechanical tampers of a type approved by +45E,=E5G/5EE, to avoid damage to structures(
,.3.26AC7FI88ING MATERIA8S a. *ac92lling materials shall be free from stones or roc9s larger than F mm$ or other material hich might prevent proper compaction or cause the compacted 2ll or emban9ment to perform inade;uately( b. *ac92lling materials shall be free from fossil content$ clay$ vegetation and its roots$ aste materials$ Material containing gypsum or other soluble salts greater than the alloable limits( c. 1olloing classi2ed materials shall not be used for bac92lling( N +rganic material$ logs stumps and perishable materials( N Material susceptible to spontaneous combustion( N Materials ith unde2ned properties( N Materials having moisture content greater than the ma@imum speci2ed( N *uilding rubble and domestic and industrial astes( N Soils and roc9 susceptible to deterioration=change of their properties( N Clay$ silt and other loose or soft soils not in accordance ith compaction criteria( N redged material( N ,oc9 materials
,.3.3FI88ING OF MATERIA8S a. 1ill material shall be spread and compacted in !FF mm layers$ ith a compacted layer thic9ness not e@ceeding !FF mm here mechanical compactors li9e vibratory plate=drum compactors are used( b. The thic9ness of 2ll material shall not e@ceed >F mm here manual compaction methods are adopted( c. /f the thic9ness of loose 2ll layers re;uired to e@ceed !FF mm ritten approval including methods of compaction shall be re;uired from the +45E,=E5G/5EE,(
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d. /f the surfaces receiving 2ll layers is smooth$ then scari2ed to obtain a good friction=9ey beteen the ne 2ll layer and the sub grade( e. E@cavated materials may only be used for bac92lling after obtaining necessary permissions or approvals from the +ner=Engineer(
,.4 F#"ati# #; Ca<0e T"e%. a. The formation of the trench shall be in accordance ith Project raings and Speci2cations( b. The trench shall be e@cavated upto the re;uired depth of F(O Mtr( from the e@isting ground level c. une sand bedding shall be done for a thic9ness of >Fmm at the bottom of the trench using T, tested and approved dune sand$ prior to the installation of cables( d. Cables are laid over the dune sand bedding e. %pproved sand=bac92ll material is 2lled in the trench to the re;uired level as per approved draing( f. SuJcient 4ater is poured to match the re;uired Moisture content g. Cable protection tiles are laid above the dune sand 2lling ,.5
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a. Ensure the Concrete Cable Tiles are securely placed( b. Selected sieved materials from the e@cavated soil shall be bac92lled for a thic9ness of DFmm above the cable protection tiles( Care shall be ta9en to avoid stones and boulders mi@ing ith the bac92ll material c. /nstall Cable 4arning Tape at a height of DFmm from top of the concrete cable tiles d. *ac92ll to the re;uired level in similar ay( e. Ensure Proper Compaction of soil is done after every >Fmm layer laid( f. ,einstate the area as to its original situation(
-.? CA68ING -.1 Mate"ia0 *a90i! a. The Material ,ECE/E 1,+M Client shall be stored in designated area of the Store=storage facility( b. %rrangements shall be made to protect the cable drums against eIects of eather and environment( c. Material inspection ill be carried out to ascertain that no damage has occurred to the Cables( d. /n case of any damages common inspection and report ill be issued( e. Cable shall be tested on cable drums prior to removal and or9 site ith a >FFF insulation tester )H for M Cables.(The values ill be noted for Core to Core and %rmour( f. %fter the test$ the end of the cable shall be sealed to prevent the ingress of moisture( g. Store material re;uisition shall be made( h. The material shall be transported in their original pac9ing to location( i. The cable drums shall be oI?loaded at the site locations as identi2ed by the site engineer( j. /t shall be ensured that there is no obstruction to movement of vehicles or any hindrance to or9s of other companies(
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Ca<0i!
-.2.1 U9e"!"#'9 Ca<0e P'00i! a. /nspection of sand bed ill be carried out prior to commencement of cable pulling( The sand bed ill be of minimum >FFmm Thic9ness( b. %fter commencement of cable pulling the trench ill be maintained clean( c. Cable rollers shall be placed as re;uired on the cable route( d. Cable inch$ if re;uired$ shall be positioned in proper place for cable pulling( e. The cable drum intended for cable pulling shall be identi2ed as per that indicated in the drum schedule( f. The cable drums shall be un?pac9ed( g. The cable shall be 2@ed to the inch$ if used$ by means of a cable soc9 or gripper( ,e;uired number of persons ill be posted at inch and near the drum( h. Cable laying ill generally start from one end of the route length or at any suitable point if re;uired( i. /n case of buildings$ the drums ill be placed outside the buildings and the cable pulled in the opposite direction( %fter reaching the other end the length of the cable re;uired for reaching the location inside the building ill be measured and then cut the cable( j. /n case of cable lengths hich are more than one drum length$ all cables hich can be laid from original position ill be completed( %nd then the cable pulling set?up ill be re?positioned to the ne@t location$ from here the ne@t length ill be pulled( 9. epending on the eight and sie of the drum$ suitable sie of the cable spindle shall be placed inside the central a@is of the drum( l. Suitable jac9s shall be placed 2rmly on the ground and jac9ed?up to allo clearance from the ground depending on the sie of the cable drum( m. The drum shall be lifted by re;uired e;uipment and placed on the jac9s( The cable drum ill be correctly positioned and the direction of cable pulling as indicated by arro on the drum shall be complied( n. Cables ill be laid = pulled by hand and = or inch( uring pulling ith inch$ if re;uired$ the tension on the cable ill not e@ceed that given by the manufacturer( o. Cables ill be pulled according to drum?cable cutting schedule and as shon in the relevant draings( p. *ending radius of cables shall comply ith cable manufacturer:s recommendation( ;. -nless the lengths e@ceed the ma@imum drum lengths joints shall be avoided(
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. %fter completion of all cables in the same route the cables shall be dressed and clamped( @. Cable
-.2.2 A<#(e G"#'9 Ca<0e P'00i! a. Cables shall be laid mainly above ground in cable trays perforated and ladder type( b. Cable rollers shall be placed at every O?>D meters or less if re;uired to avoid touching of the cable to tray( c. Cable inch$ if used$ shall be positioned in proper place for cable pulling( d. The cable drum intended for cable pulling shall be identi2ed as per that indicated in the drum schedule( e. The cable drums shall be unpac9ed( The cable shall be 2@ed to the inch by means of a cable soc9 or gripper( f. ,e;uired number of persons ill be posted at the inch$ if used$ and near the drum( g. Cable laying ill generally start from one end of the route length from other suitable point if re;uired( h. /n case of buildings$ the drums ill be placed outside the buildings and the cable pulled in the opposite direction( %fter reaching the other end the length of the cable re;uired for reaching the location inside the building ill be measured and then cut the cable( i. /n case of cable lengths hich are more than one drum length$ all cables hich can be laid from original position ill be completed( %nd then the cable pulling set?up ill be re?positioned to the ne@t location$ from here the ne@t length ill be pulled( j. epending on the eight and sie of the drum$ suitable sie of the cable rolling shaft )Spindle. shall be placed inside the central a@is of the drum( 9. Suitable jac9s shall be placed 2rm ground and jac9ed?up to allo clearance from the ground depending on the sie of the cable drum( l. The drum shall be lifted by re;uired e;uipment and placed on the jac9s(The cable drum ill be correctly positioned and the direction of cable pulling as indicated by arro on the drum shall be complied(( m. Cables ill be laid = pulled by hand and = or inch( n. Cables ill be pulled according to drum?cable cutting schedule and as shon in the relevant draings( o. *ending radius of cables shall comply to cable manufacturers recommendation( p. -nless the lengths e@ceed the ma@imum drum lengths joints shall be avoided( ;. *efore cutting the cable$ both ends must be inspected to ensure suJcient length is for proper dressing and end termination( r. Soon after completion of every cable the cables ill be tested for insulation resistance( s. The open ends ill be sealed till termination( t. Cable tags shall be installed as per Client Speci2cation u. The cable schedule and drum schedule ill be updated ith the information on cable pulling(
v. %fter completion of all cables in the same route the cables shall be dressed and clamped( Cables shall be 2@ed in horiontal or vertical runs ith or Cable ties( . /nterval of clamping ill be as per Client Speci2cation$ but ill not e@ceed >FMtr for the horiontal runs and >(FMtr for vertical runs( 4hen single core cables are used the laying shall be in three?foil formation )Trefoil.( @. %s?*uilt mar9?up draings certi2ed by Contractor:s Supervisor and Engineer ill be prepared( Cable joints position ill be shon on the draings( y. Empty cable drums ill be transported bac9 to stores(
-.2.3 C#/i9e"ati#/ a. 4here bends are encountered in a run$ cables shall be lubricated ith a cable pulling lubricant to facilitate draing in( Petroleum based is not acceptable( uring installation process cable must not be bent to a radius of less than >D times the overall diameter of the cable( These conditions shall be strictly adhered to$ particularly here cables turn into road crossings$ conduit entry etc( b. ,ollers must be used here cables are installed in an open trench using a pulling rope and eyeQ cable rollers are to be used at fre;uent intervals to support the cables and must never be more than ! meters apart( Care must be ta9en to ensure that the cable does not enter or leave the rollers at an angle that e@ceeds the bending radius of the cable( The rollers are to be pac9ed securely to prevent movement( *efore driving any spi9es to secure the rollers$ care must be ta9en to avoid other buried installations li9e cables etc( belo the trench Roor( c. The Pulling rope must be e;uipped ith a sivel and be attached to the cable by a stoc9ing grip ith pulling eye( d. The cable shall be dran into the trench manually$ before the pull commences$ to prevent the inch to move along ith the cable( The cable shall be dran into the trench smoothly ith a minimum of stops and at an average speed of ?>D meters per minute$ to avoid irregular movement(
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