METHOD STATEMENT

INDEX

1.

Excavation

2.

Fabrication and laying of MS pipes

A
B
C
D
E
F

Fabrication
Gunniting
Bedding for trenches
Laying
Hydraulic testing
In-Situ Lining

3.

Backfilling

4.

Concreting

A
B
C
D

Reinforcement
Concreting
Curing
Formwork

5.

Brick work

6.

Plastering

1.

Excavation

Carry out detailed survey of the proposed alignment, before commencing the
earth work.

Dig trial pits along the alignment as shown on the drawings in advance of the
excavations to the locate any under ground utilities or soil conditions.

Ensure proper safety arrangements before starting excavation.

Mark excavation area in proper alignment as per sketch/drawing.

Then excavate to the specified width and depth required for laying and jointing of
the pipeline and construction of permanent structure.

Maintain a minimum earth cushion of 1 m above the pipe top for underground
pipeline wherever rock is not encountered.

Safety barricading tape shall be provided wherever required.

Provide display boards giving direction for diversion of traffic at the required
places.

Adjust excavation of trenches in such lengths that the pipes can be laid in such
exposed portion of the trench as early as possible depends on soil conditions.

In case of field welding, an extra excavation of 400 mm from the bottom of

excavated level shall be excavated.

2.

Fabrication and laying of MS pipes

Reference: IS 2062 IS 3589 IS 1916

Fabrication

All the edges of the plates are cleaned & buff by brush on both the sides.

Plates are cut to size or length to have minimum wastage.

The edges of plate are smoothened with an electrical or pneumatic grinder to

remove all inequalities.

The cut edges of the plate are kept perfectly straight.

The cut plates are checked for correctness before they are rolled into pipe drums.

The plates cut to the exact size are put into a rolling machine to form a pipe of the
required diameter.

The rolling machine is adjusted to give a uniform curvature to the pipe throughout
its circumference.

The rolled drums are kept on an assembly for tacking with their end faces at right
angles to the axis of the pipe.

A gap of 2 mm to 4 mm is maintained while tacking the drum for hand welding.

Join 5 pipes of 1.2 m length each by seal welding.

Submerged arc welding is done inside and outside the pipe and its is kept ready
for hydro testing after weld joints are inspected by ultrasonic testing as per
specification.

Pipes are tested at hydraulic pressure of 1.5 times of working pressure and
pressure shall be applied for 10 seconds.

If any leak or sweating is observed in the weld joints, the same is repaired and
retested to confirm the specified pressure.

Gunniting

On receipt of the hydro tested fabricated pipes, clean the pipes by using wire
brush to make pipe surface free from rust, debris, mud, dirt, mill scales etc.

Place the MS pipe over sleepers to ensure sufficient gap from ground level.

Tie the 50 x 50 mm 13 gauge weld mesh on the surface after placing 10-12 mm
cover blocks cast in CM 1:1:5 and ensure proper lapping of weld mesh.

Maintain a cut back length of 75 to 100 mm for field joint.

Prepare the cement mortar by mix.

Feed the cement sand dry mixture into mechanical feeder.

Then convey by compressed air through delivery hose to the nozzle which is
fitted inside a perforated manifold through which water is introduced under
pressure and intimately mixed with the cement sand mixer.

Jet the mortar from the nozzle at high velocity on the surface of pipe.

Obtain the required thickness and suitable surface finish.

Ensure the thickness of coating regularly during the process by using spike gauge.

Start curing operation only after 24 hours.

Carryout curing for 7 days by sprinklers and by hose where sprinkled water is not
reaching.

After the outer coated pipe has attained required strength, it shall be dispatched to
site for laying.

Bedding for trenches

Provide bedding as per approved drawings.

Use selected available earth from trench excavation and foundation for bedding of
pipeline trenches and foundations.

Compact for 150-200 mm thick using manual tamping / mechanical vibration.

Provide earth/murrum bedding when a rock is met with.

Provide special bedding using gravel/in poor sub grades.

Laying

Laying of pipes and fittings is done after excavation of trenches and proper
bedding for pipes.

Pipes are carefully lowered into the trenches by mobile cranes / tripods.

When pipe laying is not in progress, the open ends of the pipe shall be covered
with plywood/plastic sheets.

Cutting of pipes for inserting valves or fittings is done without any damage to
pipe.

Fit up of each joint to be checked for bevel angle, root face and root gap as per
specification.

After completion of root run, deposited slag over it to be removed before

intermediate passes.

After completion of field joint welding, outer coating of joints to be done

manually and apply curing compound over it to ensure self curing.

Hydraulic testing

Carryout hydraulic test after the pipeline section to be tested is laid.

Subject pipelines and fittings to hydraulic pressure tests in the presence of the
engineer.

The section to be tested shall be of 600 mtr and above.

Use test gauges of approved manufacture, having dials at least 200 mm diameter,
graduated such that the test pressure is at least 75% of the full scale reading.

All gauges should be dead weight tested and calibrated at the commencement of
work and at regular intervals.

Arrangements for testing should include a suitable means of quick installation and
removal of the gauges during testing..

Each length of the pipeline to be tested is capped or blanked off at each end and
securely strutted or restrained to withstand the forces which will be exerted when
the test pressure is applied.

Do not permit any welding on testing pipe.

The length under test should be filled making certain that all air is displaced
through an air valve installed at the top of the blank flange situated at the high end
of the line.

The field test pressure shall be 1.5 times the working pressure.

The test on completion shall be carried out after all the pipeline sections have
been satisfactorily tested and the joints between each section completed to
provide a continuous test length between contract interfaces.

In-situ lining

In situ lining shall be carried out after laying and hydraulic testing of the pipeline.

In situ lining shall be carried out in 300 to 500 m stretch at a time.

Cement mortar as per design mix by using mixer machine (CM 1:2 ratio) and
controlled water cement ratio.

Lining shall be carried out with special type in situ lining machine.

3.

Backfilling

The space between the side of excavated pit and the pipe has to be backfilled with
selected available earth.

Before starting backfilling, ensure that all loose materials such wooden runners
etc. have been removed thoroughly.

Backfill the areas in layers.

Extra available earth shall be kept over the pipeline trench to avoid any future
settlement or to avoid any soil erosion.

4.

Concreting:

Reinforcement

Reinforcement shall be clean and free of rust, mud and oil.

Reinforcement shall confirm to the details given in bar bending schedule which in
turn should have been prepared from the good for construction drawings and got
approved from the client engineers.

Position the reinforcement and check if they have been tied correctly. Also ensure
that the size of bar, spacing between bars, correct bends, proper laps, curtailment
of bars, type of binding wire, adequate binding, welding or splicing, binding wire
bend inside, enough chairs kept in proper position and cover blocks are all in
order. If note the same rectified, if found to be in order certify the pour card for
placement of reinforcement check.

Responsibility: reinforcement in charge/site engineer/QA engineer.

Concreting

Concrete of required grade and workability should be poured within one hour
since mixing. Check trip sheet before unloading.

Concrete should not segregate while conveying and placing.

Concrete should be placed as near as possible to its final location. Do not move
concrete over long distances using vibrator.

For large areas and having several layers such as mass foundations, place concrete
systematically in a stair step manner.

For placing concrete on a slope, placing should start at the bottom and move up.

Concrete mixing shall be done as per mix design with weigh batching mixer
machine.

Concrete should be placed in layers not exceeding 300 mm and compacted using
immersion type needle vibrators.

Always use vertical drop chute at the end of sloping chutes to avoid segregation.

Vibrator should be applied systematically to cover all areas immediately after

placing concrete.

The vibrator needle should penetrate the layer of concrete vertically and into the
under lying layer previously placed and vibrated if possible.

Stop vibrating when the concrete flattens and takes up glistering appearance, the
rise of entrapped air ceases, the coarse aggregate blends into the surface but does
not completely disappear and the vibrator after an initial slowdown when inserted
resumes its speed.

Withdraw the vibrator slowly to ensure closing of the hole resulting from
insertion.

Always follow correct placing and techniques.

Ensure that the top layer of concrete is as required and finished suitably.

Ensure that the concrete ahs been sampled for workability test and cube casting.
The details should be recorded. Frequency of sampling should be as per technical
specification or IS 456.

Responsibility: Site Engineers / QA Engineer.

Curing

Use potable / river / bore well water for curing.

For large unformed area structures like slabs, mass foundation starts curing as
soon as concrete has set.

For formed surfaces start curing as soon as formwork is removed.

Cure concrete till it achieves the design strength.

Select material to suit the required finish of concrete as per specifications.

Form work

Form work shall be strong enough to withstand pressure or weight of fresh

concrete and other load like vibration etc. without distortion, leakage, failure or
danger to workmen.

Before starting erection, check the shutters are properly cleaned, old concrete and
protruding nails etc. removed.

The sequence of form fixing shall be co-related with fixing of inserts, sleeves,
conduits, anchors and the work of reinforcement placing.

Prepare a check list for checking of formwork prior to concreting as per the
format given in pour card and take the approval.

Check the location, dimension, line etc.

Formwork should be continuously watched during and after concreting by the

concerned person.

In case of leakages, bulging and sagging, promptly make adjustments by

tightening wedges or adjusting by jacking but all adjustments must be made
before the concrete takes its initial set.

Remove forms after the minimum period stipulated in specifications or as per IS

456.

Ensure that the concrete surface is not damaged while de-shuttering and the
concrete is cast within the tolerance limit as per specifications.

The sequence of de-shuttering should be as specified and shall ensure that there is
no overstressing of formwork or permanent structure.

Check the line level, plumb etc. after de shuttering and record the deviations and
plan for correction if required in subsequent pours.

Rectify all blemishes and defects, if any, immediately.

Clean the stack the removed formwork materials properly for its next use.

5.

Brick work

Bricks for masonry works shall conform to IS specification for physical

requirement, quality, dimensions, tolerances etc.

The bricks shall be regular in shape and size with sharp edges and corners. They
shall be of uniform deep red or copper colour free from cracks, chips,
efflorescence, flaws and lumps of any kind.

Locally available bricks of non modular sizes can be used in case the bricks
satisfy the other requirements of IS.

For cement mortar, cement shall be fresh Portland cement of standard quality.
Sand shall be medium coarse sand, clean, sharp and free from clay, mica or
organic matter.

Water used shall be clean and reasonably free from oils, acids, alkalis, salts and
vegetable growth. Generally potable water shall be used.

The brickwork shall be done with the specified mortar (cement or lime) mixing
the ingredients in the specified proportion.

The brickwork shall be true to line, plumb and all vertical joints shall be truly
vertical. Vertical joints in alternate courses shall come directly one over the other.

Thickness of brick course shall be kept uniform. All iron fixtures, pipes, outlets of
water, hold fasts of doors and windows, which are required to be built into wall
shall be embedded in mortar or cement concrete as specified in their correct
position as per direction as the work proceeds.

Masonry work in cement mortar or lime mortar shall be kept constantly moist on
all faced for a minimum period of seven days.

6.

Plastering

Cement shall conform to IS 269 sand shall be free from excessive deleterious
materials. Water for plaster shall conform to IS 456 shall be from acids, alkalis,
chlorides etc.

Cement mortar shall be prepared by mixing cement, sand by volume conforming

to brick masonry and meet the requirements of IS:2250. Proportion of cement and
sand shall be as specified shown on the drawings. The dry mixing of cement sand
mortar shall be done by hand mixing.

Plastering operations shall be started from top side and carried downwards. In
case of two layer plasters work the specified thickness under layer shall be
scarified while green and subsequent coat shall be applied after allowing
minimum three days setting of first layer.

Curing shall be commenced 24 hours after finishing the plaster and continued for
seven days. Surfaces shall be protected from all the damages.

The stage payment for different works shall be as follows:

1.

MS Pipeline works
*
*
*
*
*
*

2.

10% Mobilization advance along with order

60% on fabrication of pipe.
5% on gunniting of pipe.
3% on lining of pipeline.
20% on excavation and laying of pipeline.
2% on hydro testing of pipeline.

Civil works.
10% mobilization advance along with order & balance 90% payment shall be
released after completion for civil works. Detailed item wise/stage payment break
up for individual structures shall be provided after award of the works.

3.

The following shall be arranged by JSW STEEL LTD.

Clear access required for the entire 166.5 KM/actual length of pipeline and
adequate land required for intake structure, intermediate pumping station, break
pressure tank, river crossing structure and any other structures required for the
project without any hindrance and encumbrance.

Access and approach road to site.

Land required for temporary site installations.

Please note that we shall not be in a position to take up the responsibility of getting the
necessary clearances/approvals either from Government Authorities or from private land
owners for obtaining the right of way on behalf of the owner. However we shall provide
all technical support to JSW to get these clearances from respective authorities.
4.

We have submitted our offer considering the entire work in our scope. In the event
of the said job being divided for whatsoever reasons, we shall reserve our right to
revised our quoted rates & prices.

5.

In the event of the owner not providing the ROW on time commensurate upto the
progress required to be achieved for completion of the work, then, apart from the
time extension, all idling charges on account of all resources like labour, plant and
machinery, materials, supervision and all such losses shall be suitably
compensated after mutual discussions including a reasonable profit.

6.

The prices and the rates quoted by us shall remain firm during the entire duration
of contract provided the right of way for the entire pipeline alignment and land for
other structures are given to us right from day one of the award of the job and the
contract period remains as a total of 24 months from the date of award of work. In
the event of work being delayed on account of not obtaining right of way by client
either partially or fully, leading to execution of work beyond the prescribed 24
months period, then the quoted price shall be negotiable upwards mutually so as
to compensate suitably.

7.

In case of any change in the location of source, pumping stations or any major
variation in the pipeline alignment, the price quoted by us shall be subject to
revision on mutual discussions and settlement.

8.

All drawings, design calculations or other documents shall be approved within

seven days of submission. Delays beyond this may lead to delays in completion.

9.

We have not envisaged working under waterlogged condition.

10.

Our offer is valid for a period of 60 days from the date of submission of our offer.