METHOD STATEMENT
INDEX
1.
Excavation
2.
Fabrication and laying of MS i!"
A B C D E F
Fabrication Gunniting Bedding for trenches Laying Hydraulic testing In-Situ Lining
#.
$ac%filling
&.
'oncr!ting
A B C D
Reinforceent Concreting Curing For!or"
(.
$ric% )or%
*.
+la"t!ring
1.
Excavation
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Carry out detailed sur$ey of the %ro%osed alignent& before coencing the earth !or"'
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Dig trial %its along the alignent as sho!n on the dra!ings in ad$ance of the e(ca$ations to the locate any under ground utilities or soil conditions'
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Ensure %ro%er safety arrangeents before starting e(ca$ation'
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)ar" e(ca$ation area in %ro%er alignent as %er s"etch*dra!ing'
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+hen e(ca$ate to the s%ecified !idth and de%th re,uired for laying and ointing of the %i%eline and construction of %eranent structure'
#
)aintain a iniu earth cushion of . abo$e the %i%e to% for underground %i%eline !here$er roc" is not encountered'
#
Safety barricading ta%e shall be %ro$ided !here$er re,uired'
#
/ro$ide dis%lay boards gi$ing direction for di$ersion of traffic at the re,uired %laces'
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Adust e(ca$ation of trenches in such lengths that the %i%es can be laid in such e(%osed %ortion of the trench as early as %ossible de%ends on soil conditions'
#
In case of field !elding& an e(tra e(ca$ation of 011 fro the botto of e(ca$ated le$el shall be e(ca$ated'
2.
Fabrication and laying of MS i!" Reference2 IS 3143 IS 5678 IS .8.4
A
Fabrication
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All the edges of the %lates are cleaned 9 buff by brush on both the sides'
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/lates are cut to si:e or length to ha$e iniu !astage'
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+he edges of %late are soothened !ith an electrical or %neuatic grinder to reo$e all ine,ualities'
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+he cut edges of the %late are "e%t %erfectly straight'
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+he cut %lates are chec"ed for correctness before they are rolled into %i%e drus'
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+he %lates cut to the e(act si:e are %ut into a rolling achine to for a %i%e of the re,uired diaeter'
#
+he rolling achine is adusted to gi$e a unifor cur$ature to the %i%e throughout its circuference'
#
+he rolled drus are "e%t on an assebly for tac"ing !ith their end faces at right angles to the a(is of the %i%e'
#
A ga% of 3 to 0 is aintained !hile tac"ing the dru for hand !elding'
#
;oin 6 %i%es of .'3 length each by seal !elding'
#
Suberged arc !elding is done inside and outside the %i%e and its is "e%t ready for hydro testing after !eld oints are ins%ected by ultrasonic testing as %er s%ecification'
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/i%es are tested at hydraulic %ressure of .'6 ties of !or"ing %ressure and %ressure shall be a%%lied for .1 seconds'
#
If any lea" or s!eating is obser$ed in the !eld oints& the sae is re%aired and retested to confir the s%ecified %ressure'
$
,-nniting
#
/lace the )S %i%e o$er slee%ers to ensure sufficient ga% fro ground le$el'
#
+ie the 61 ( 61 .5 gauge !eld esh on the surface after %lacing .1-.3 co$er bloc"s cast in C) .2.26 and ensure %ro%er la%%ing of !eld esh'
#
)aintain a cut bac" length of =6 to .11 for field oint'
#
/re%are the ceent ortar by i('
#
Feed the ceent sand dry i(ture into echanical feeder'
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+hen con$ey by co%ressed air through deli$ery hose to the no::le !hich is fitted inside a %erforated anifold through !hich !ater is introduced under %ressure and intiately i(ed !ith the ceent sand i(er'
#
;et the ortar fro the no::le at high $elocity on the surface of %i%e'
#
#
Ensure the thic"ness of coating regularly during the %rocess by using s%i"e gauge'
#
Start curing o%eration only after 30 hours'
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Carryout curing for = days by s%rin"lers and by hose !here s%rin"led !ater is not reaching'
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After the outer coated %i%e has attained re,uired strength& it shall be dis%atched to site for laying'
'
$!dding for tr!nc/!"
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/ro$ide bedding as %er a%%ro$ed dra!ings'
#
>se selected a$ailable earth fro trench e(ca$ation and foundation for bedding of %i%eline trenches and foundations'
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Co%act for .61-311 thic" using anual ta%ing * echanical $ibration'
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/ro$ide earth*urru bedding !hen a roc" is et !ith'
#
/ro$ide s%ecial bedding using gra$el*in %oor sub grades'
D
0aying
#
Laying of %i%es and fittings is done after e(ca$ation of trenches and %ro%er bedding for %i%es'
#
/i%es are carefully lo!ered into the trenches by obile cranes * tri%ods'
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?hen %i%e laying is not in %rogress& the o%en ends of the %i%e shall be co$ered !ith %ly!ood*%lastic sheets'
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Cutting of %i%es for inserting $al$es or fittings is done !ithout any daage to %i%e'
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Fit u% of each oint to be chec"ed for be$el angle& root face and root ga% as %er s%ecification'
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After co%letion of root run& de%osited slag o$er it to be reo$ed before interediate %asses'
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After co%letion of field oint !elding& outer coating of oints to be done anually and a%%ly curing co%ound o$er it to ensure self curing'
E
Hydra-lic t!"ting
#
Carryout hydraulic test after the %i%eline section to be tested is laid'
#
Subect %i%elines and fittings to hydraulic %ressure tests in the %resence of the engineer'
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+he section to be tested shall be of 411 tr and abo$e'
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>se test gauges of a%%ro$ed anufacture& ha$ing dials at least 311 diaeter& graduated such that the test %ressure is at least =6@ of the full scale reading'
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All gauges should be dead !eight tested and calibrated at the coenceent of !or" and at regular inter$als'
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Arrangeents for testing should include a suitable eans of ,uic" installation and reo$al of the gauges during testing''
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Each length of the %i%eline to be tested is ca%%ed or blan"ed off at each end and securely strutted or restrained to !ithstand the forces !hich !ill be e(erted !hen the test %ressure is a%%lied'
#
Do not %erit any !elding on testing %i%e'
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+he length under test should be filled a"ing certain that all air is dis%laced through an air $al$e installed at the to% of the blan" flange situated at the high end of the line'
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+he field test %ressure shall be .'6 ties the !or"ing %ressure'
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+he test on co%letion shall be carried out after all the %i%eline sections ha$e been satisfactorily tested and the oints bet!een each section co%leted to %ro$ide a continuous test length bet!een contract interfaces'
F
In"it- lining
In situ lining shall be carried out after laying and hydraulic testing of the %i%eline'
#
In situ lining shall be carried out in 511 to 611 stretch at a tie'
#
Ceent ortar as %er design i( by using i(er achine C) .23 ratio and controlled !ater ceent ratio'
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Lining shall be carried out !ith s%ecial ty%e in situ lining achine'
#.
$ac%filling
#
+he s%ace bet!een the side of e(ca$ated %it and the %i%e has to be bac"filled !ith selected a$ailable earth'
#
Before starting bac"filling& ensure that all loose aterials such !ooden runners etc' ha$e been reo$ed thoroughly'
#
Bac"fill the areas in layers'
#
E(tra a$ailable earth shall be "e%t o$er the %i%eline trench to a$oid any future settleent or to a$oid any soil erosion'
&.
'oncr!ting
A
3!inforc!4!nt
#
Reinforceent shall be clean and free of rust& ud and oil'
#
Reinforceent shall confir to the details gi$en in bar bending schedule !hich in turn should ha$e been %re%ared fro the good for construction dra!ings and got a%%ro$ed fro the client engineers'
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/osition the reinforceent and chec" if they ha$e been tied correctly' Also ensure that the si:e of bar& s%acing bet!een bars& correct bends& %ro%er la%s& curtailent of bars& ty%e of binding !ire& ade,uate binding& !elding or s%licing& binding !ire bend inside& enough chairs "e%t in %ro%er %osition and co$er bloc"s are all in order' If note the sae rectified& if found to be in order certify the %our card for %laceent of reinforceent chec"'
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Res%onsibility2 reinforceent in charge*site engineer*A engineer'
$
'oncr!ting
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Concrete of re,uired grade and !or"ability should be %oured !ithin one hour since i(ing' Chec" tri% sheet before unloading'
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Concrete should not segregate !hile con$eying and %lacing'
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Concrete should be %laced as near as %ossible to its final location' Do not o$e concrete o$er long distances using $ibrator'
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For large areas and ha$ing se$eral layers such as ass foundations& %lace concrete systeatically in a stair ste% anner'
#
For %lacing concrete on a slo%e& %lacing should start at the botto and o$e u%'
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Concrete i(ing shall be done as %er i( design !ith !eigh batching i(er achine'
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Concrete should be %laced in layers not e(ceeding 511 and co%acted using iersion ty%e needle $ibrators'
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Al!ays use $ertical dro% chute at the end of slo%ing chutes to a$oid segregation'
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ibrator should be a%%lied systeatically to co$er all areas iediately after %lacing concrete'
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+he $ibrator needle should %enetrate the layer of concrete $ertically and into the under lying layer %re$iously %laced and $ibrated if %ossible'
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Sto% $ibrating !hen the concrete flattens and ta"es u% glistering a%%earance& the rise of entra%%ed air ceases& the coarse aggregate blends into the surface but does not co%letely disa%%ear and the $ibrator after an initial slo!do!n !hen inserted resues its s%eed'
#
?ithdra! the $ibrator slo!ly to ensure closing of the hole resulting fro insertion'
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Al!ays follo! correct %lacing and techni,ues'
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Ensure that the to% layer of concrete is as re,uired and finished suitably'
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Ensure that the concrete ahs been sa%led for !or"ability test and cube casting' +he details should be recorded' Fre,uency of sa%ling should be as %er technical s%ecification or IS 064'
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Res%onsibility2 Site Engineers * A Engineer'
'
'-ring
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>se %otable * ri$er * bore !ell !ater for curing'
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For large unfored area structures li"e slabs& ass foundation starts curing as soon as concrete has set'
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For fored surfaces start curing as soon as for!or" is reo$ed'
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Cure concrete till it achie$es the design strength'
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Select aterial to suit the re,uired finish of concrete as %er s%ecifications'
D
For4 )or%
#
For !or" shall be strong enough to !ithstand %ressure or !eight of fresh concrete and other load li"e $ibration etc' !ithout distortion& lea"age& failure or danger to !or"en'
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Before starting erection& chec" the shutters are %ro%erly cleaned& old concrete and %rotruding nails etc' reo$ed'
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+he se,uence of for fi(ing shall be co-related !ith fi(ing of inserts& slee$es& conduits& anchors and the !or" of reinforceent %lacing'
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/re%are a chec" list for chec"ing of for!or" %rior to concreting as %er the forat gi$en in %our card and ta"e the a%%ro$al'
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Chec" the location& diension& line etc'
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For!or" should be continuously !atched during and after concreting by the concerned %erson'
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In case of lea"ages& bulging and sagging& %ro%tly a"e adustents by tightening !edges or adusting by ac"ing but all adustents ust be ade before the concrete ta"es its initial set'
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Reo$e fors after the iniu %eriod sti%ulated in s%ecifications or as %er IS 064'
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Ensure that the concrete surface is not daaged !hile de-shuttering and the concrete is cast !ithin the tolerance liit as %er s%ecifications'
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+he se,uence of de-shuttering should be as s%ecified and shall ensure that there is no o$erstressing of for!or" or %eranent structure'
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Chec" the line le$el& %lub etc' after de shuttering and record the de$iations and %lan for correction if re,uired in subse,uent %ours'
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Rectify all bleishes and defects& if any& iediately'
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Clean the stac" the reo$ed for!or" aterials %ro%erly for its ne(t use'
(.
$ric% )or%
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Bric"s for asonry !or"s shall confor to IS s%ecification for %hysical re,uireent& ,uality& diensions& tolerances etc'
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+he bric"s shall be regular in sha%e and si:e !ith shar% edges and corners' +hey shall be of unifor dee% red or co%%er colour free fro crac"s& chi%s& efflorescence& fla!s and lu%s of any "ind'
#
Locally a$ailable bric"s of non odular si:es can be used in case the bric"s satisfy the other re,uireents of IS'
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For ceent ortar& ceent shall be fresh /ortland ceent of standard ,uality' Sand shall be ediu coarse sand& clean& shar% and free fro clay& ica or organic atter'
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?ater used shall be clean and reasonably free fro oils& acids& al"alis& salts and $egetable gro!th' Generally %otable !ater shall be used'
#
+he bric"!or" shall be done !ith the s%ecified ortar ceent or lie i(ing the ingredients in the s%ecified %ro%ortion'
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+he bric"!or" shall be true to line& %lub and all $ertical oints shall be truly $ertical' ertical oints in alternate courses shall coe directly one o$er the other'
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+hic"ness of bric" course shall be "e%t unifor' All iron fi(tures& %i%es& outlets of !ater& hold fasts of doors and !indo!s& !hich are re,uired to be built into !all shall be ebedded in ortar or ceent concrete as s%ecified in their correct %osition as %er direction as the !or" %roceeds'
#
)asonry !or" in ceent ortar or lie ortar shall be "e%t constantly oist on all faced for a iniu %eriod of se$en days'
*.
+la"t!ring
#
Ceent shall confor to IS 348 sand shall be free fro e(cessi$e deleterious aterials' ?ater for %laster shall confor to IS 064 shall be fro acids& al"alis& chlorides etc'
#
Ceent ortar shall be %re%ared by i(ing ceent& sand by $olue conforing to bric" asonry and eet the re,uireents of IS23361' /ro%ortion of ceent and sand shall be as s%ecified sho!n on the dra!ings' +he dry i(ing of ceent sand ortar shall be done by hand i(ing'
#
/lastering o%erations shall be started fro to% side and carried do!n!ards' In case of t!o layer %lasters !or" the s%ecified thic"ness under layer shall be scarified !hile green and subse,uent coat shall be a%%lied after allo!ing iniu three days setting of first layer'
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Curing shall be coenced 30 hours after finishing the %laster and continued for se$en days' Surfaces shall be %rotected fro all the daages'
T/! "tag! ay4!nt for diff!r!nt )or%" "/all b! a" follo)" .'
)S /i%eline !or"s # # # # # #
3'
.1@ )obili:ation ad$ance along !ith order 41@ on fabrication of %i%e' 6@ on gunniting of %i%e' 5@ on lining of %i%eline' 31@ on e(ca$ation and laying of %i%eline' 3@ on hydro testing of %i%eline'
Ci$il !or"s' .1@ obili:ation ad$ance along !ith order 9 balance 81@ %ayent shall be released after co%letion for ci$il !or"s' Detailed ite !ise*stage %ayent brea" u% for indi$idual structures shall be %ro$ided after a!ard o f the !or"s'
5'
+he follo!ing shall be arranged by ;S? S+EEL L+D'
#
Clear access re,uired for the entire .44'6 )*actual length of %i%eline and ade,uate land re,uired for inta"e structure& interediate %u%ing station& brea" %ressure tan"& ri$er crossing structure and any other structures re,uired for the %roect !ithout any hindrance and encubrance'
#
Access and a%%roach road to site'
#
Land re,uired for te%orary site installations'
/lease note that !e shall not be in a %osition to ta"e u% the res%onsibility of getting the necessary clearances*a%%ro$als either fro Go$ernent Authorities or fro %ri$ate land o!ners for obtaining the right of !ay on behalf of the o!ner' Ho!e$er !e shall %ro$ide all technical su%%ort to ;S? to get these clearances fro res%ecti$e authorities'
0'
?e ha$e subitted our offer considering the entire !or" in our sco%e' In the e$ent of the said ob being di$ided for !hatsoe$er reasons& !e shall reser$e our right to re$ised our ,uoted rates 9 %rices'
6'
In the e$ent of the o!ner not %ro$iding the R on tie coensurate u%to the %rogress re,uired to be achie$ed for co%letion of the !or"& then& a%art fro the tie e(tension& all idling charges on account of all resources li"e labour& %lant and achinery& aterials& su%er$ision and all such losses shall be suitably co%ensated after utual discussions including a reasonable %rofit'
4'
+he %rices and the rates ,uoted by us shall reain fir during the entire duration of contract %ro$ided the right of !ay for the entire %i%eline alignent and land for other structures are gi$en to us right fro day one of the a!ard of the ob and the contract %eriod reains as a total of 30 onths fro the date of a!ard of !or"' In the e$ent of !or" being delayed on account of not obtaining right of !ay by client either %artially or fully& leading to e(ecution of !or" beyond the %rescribed 30 onths %eriod& then the ,uoted %rice shall be negotiable u%!ards utually so as to co%ensate suitably'
='
In case of any change in the location of source& %u%ing stations or any aor $ariation in the %i%eline alignent& the %rice ,uoted by us shall be subect to re$ision on utual discussions and settleent'
7'
All dra!ings& design calculations or other docuents shall be a%%ro$ed !ithin se$en days of subission' Delays beyond this ay lead to delays in co%letion'
8'
?e ha$e not en$isaged !or"ing under !aterlogged condition'
.1'