CONSTRUCTION AND COMPLETION OF PROPOSED 800mm ND MSCL

PIPELINE FROM NYABAU WATER TREATMENT PLANT TO KIDURONG

INDUSTRIAL ESTATE, BINTULU DIVISION, SARAWAK.
Contract No.: JBALB/HQ/K017/2018

METHOD STATEMENT
OF
PIPE BRIDGE LAUNCHING

(SG SEBATANG)

Contractor:
H.K.K & SALEM CONSTRUCTION SDN BHD

1ST FLOOR,14 RAMINWAY,

96000,SIBU,SARAWAK.

TEL : 084-333123/339089

FAX : 084-333621
 TABLE OF CONTENTS

1.0 INTRODUCTION
2.0 REFERENCE
3.0 MACHINERIES & MATERIAL RESOURCES
4.0 METHOD OF CONSTRUCTION
5.0 SAFETY, HEALTH & ENVIRONMENT COMPLIANCE
6.0 APPENDICES
1.0 INTRODUCTION

The project of Construction and Completion of Proposed 800mm ND MSCL Pipeline from
Nyabau Water Treatment Plant to Kidurong Industrial Estate, Bintulu Division, Sarawak
is implemented by Jabatan Bekalan Air Luar Bandar (JBALB). The site of proposed works
is along Jalan Bukit Nyabau and Jalan Kidurong where the total pipe route is around
9.71km following by road side within road reserve from Nyabau Treatment Plant. Pipe
route A along Jalan Bukit Nyabau is about 3.5km and Pipe route B along Jalan Kidurong
is about 6.21km.

2.0 PIPE BRIDGE LAUNCHING AT SG SEBATANG

The document describes the typical construction method with its governing vectors to
enable the work to be executed smoothly and efficiently. The details of the documents may
be refined, enriched and further improvised based on the actual site scenario and
requirements. This document comprises the following:

 Machinery & Material Resources

 Construction Method Statement
 Safety, Health & Environment Compliance
 Traffic Management Plan as per Attachment A

3.0 MACHINERIES AND MATERIAL RESOURCES

 Mobile Crane (45 Tan)

 800mm diameter MSCL pipes × 9.3m long (13mm thickness)
 Welding machine and welding rod
 Excavator
 Backhoe
 Lorry / Truck
 Genset
 Piling Rig
 200 x 200 mm RC. Square Pile
 Cable detector
 Bubble level
 Mild steel angle bar
 Lifting sling
4.0 CONSTRUCTION METHOD STATEMENT

1. Setting Out
 Prior to any commencement of any physical works, a professional land surveyor shall
be appointed to carry out demarcation works and establish temporary bench marks on
site, upon obtaining all the necessary survey data. A joint survey to check existing
ground levels shall be carried out under the inspection of resident engineer.
 As for pipe bridge, the piling point for each pipe support shall be pegged and jointly
reviewed and confirmed by resident engineer.

2. Preparation on Site
 When any material is disposed outside the site, the disposal material shall be graded to
a neat appearance and shall not obstruct natural drainage or cause damage to road
highways or property. All precautions shall be taken to prevent any erosion of the soil
on the affected areas.
 All unsuitable material and surplus suitable material shall be run to spoil in tips
approved by the engineer.
 All necessary machineries, materials and resources shall be mobilized to site
accordingly.
 Temporary bridges, barriers, traffic signals, lighting, reflective warning signs and
watchmen shall be provided to ensure the safety and convenience to public users.

3. Sequence of Construction
 The following details describe the method of construction for concrete pipe support
and pipe bridge launching:

5.1 Piling Works

- Prior to the piling works for concrete pipe support, piling points shall first be set
out by the surveyor to ensure that all piles installed are as per indicated on the
construction drawings.
- The piling rig shall be hydraulic drop hammer type.
- During piling operation, the 200 x 200 mm RC. Square pile will be picked up by
 the piling machine using the lifting cable. The lifting sequence will be such that one
end of the piles will be raised (pile head) while other end is lowered down in order
to make the piles up right.
- The pile shall be guided to the pile position and lowered down to the correct peg
set by the surveyor on the ground.
- The hammer with the helmet shall then be lowered down and mounted on top the
pile head.
- The pile shall be guided to ensure vertically before driving begins. Verticality of
the pile shall be maintained by using bubble level.
- Bubble level and plywood template cut to required angle will be used when driving
raked pile.
- Initially, pile driving will start with small blows and will continue to drive until it
meets driving criteria specified by engineer.
- When extension of piles is required, joint plates are to be cleaned thoroughly form
mud, dust, oil and other detrimental to the welding.
- Align two piles such that the end plates must bear over their complete areas. The
two end plates are then welded along their entire periphery with weld size as
specified in the shop drawing provided by RC pile’s manufacturer.
- The piling rig shall be moved to another pile position for the installation of the new
pile.

5.2 Reinforced Concrete Works

- Laying of 50mm thickness of lean concrete shall be done before cutting off the pile
head.
- Installation of the steel reinforcement and formwork for the pile cap or footing of
the pipe support shall be done with the supervision from the engineer. Then,
proceed with the concreting works and inspection for post-concreting shall be done
2-3 days after the concreting.
- Then, installation of steel reinforcement and formwork for the column of pipe
support shall be done with the supervision from the engineer. Then, proceed with
the concreting works and inspection for post-concreting shall be done 2-3 days after
 the concreting.
- Inspection to the concreted footing and column shall be done in order to detect any
minor and major defect for immediate rectification work.

5.3 Delivery, Handling and Stringing of MSCL Pipes

- Pipe shall be sufficiently secured and supported using wooden stoppers and held
firmly using straps during transit.
- Lifting of pipes shall be using canvas slings to avoid damages to the external
coating.
- The pipes shall be strung along the proposed pipeline routes.

5.4 Welding Works

- Before the pipe bridge launching, the 800mm MSCL pipe shall be welded internally
and externally as required by the JKR Standards of Specification.
- Before placing the pipes together, the portion of the socket and spigot to be welded
will be cleaned to a metallic finish, the spigot end will be placed in the socket and
pushed inside to the required engagement depth.
- Where pipes are to be joined by a steel collar, the pipe ends shall be cleaned to a
metallic finish. The collar will then be placed on the joint so that the distance
between each pipe end and the collar centreline will be about 25mm. the collar shall
then be clamped tightly onto the pipes using the lugs and welded longitudinally.
- The weld shall then be cleaned using wire brush, removing any slags and welding
debris.
- Air test shall be carried out with up to 1.7 MPa pressure applied to the welding joint
for a duration of 20 minutes. Any welding defects observed will be repaired until
there is no more air leakage.
- Upon welding of joints, the bare metal joints will be thoroughly cleaned to a
metallic finish and coated using primer solutions and wrapped using Bitumen
Wrap.
- For the internal pipe joint, cement lining of mix 1:3 will be applied on all bare
metals to the same thickness of the existing pipe cement lining.
 5.5 Lifting of MSCL Pipe to the Concrete Pipe Support
- The 45T outrigger crane used to lift Pipe Bridge has capacity of 11.5 tonnes when
operating in 7m radius.
- Lifting of pipes to the concrete pipe support shall be using canvas slings to avoid
damage to the external coating and prevent the sliding of slings.
- Two slings point shall be applied to the pipe at 6m from the end pipe in order to
achieve the centre of gravity while lifting.
- Mild steel angle bar shall be placed on the concrete pipe support to achieve gradient
of the MSCL pipe by placing angle bar such that, 6 no. of angle bar on the one pipe
side; 4 no. placed at middle pipe support and 2 no. of angle bar on the other side of
the pipe bridge.
- Bubble levels or spirit levels shall be used to maintain the verticality of the pipes.

Method of lifting are as follows:

1. Mark out the position of the base machine using road marking paint.
2. Ensure the erection area is cleared sufficiently to permit the safe assembly of the
crane.
3. Drive the machine into the working position.
4. Raise suspension and engage suspension locks
5. Position matting
6. Extend outriggers into position and pin as required.
7. Slide pans into lifting position and pin
8. Lower jacks until all wheels are clear of the floor and the machine is level
9. Raise boom clear of the cradle to minimum angle of 60⁰
10. Slew round into the ballast pick up position, lower rams to engage ballast, raise into
locked position
11. Extend boom to required length
12. Perform function test on over hoist switch and slew 360⁰ to check level, re level
crane if required.
13. Crane ready for work.
 Hook Block with Safety Latch

8m x 20Tonnes Canvas Sling

10m 15.4 Tonnes Work Load 10m

Length = 32m

NOTES
1. All non-essential personnel should keep out of the working area during assembly, operation and
disassembly of the crane.
2. Safety factor of the crane load is 1.49
5.0 SAFETY HEALTH AND ENVIRONMENT COMPLIANCE
Workers & Operators
 Operator with valid driving license with certificate of competency.
 Alcohol and drug were strictly prohibited from project area.
 Usage of PPE are mandatory to be used at all time when entering work site based on
activity involved.

Sub-Contractors
 Conduct Safety Toolbox meeting.

Equipment
 Ensure equipment in proper working condition and well maintained.
 Equipped with fire extinguisher.
 Daily equipment checks before commencement of work.
 Only authorized specialists are allowed to repair, maintain, clean and execute
modification on the machines.

Safety Precautions

1. Pilot Trenching
Activity Hazard Safety Precaution
Pilot trenching 1. Underground 1. Excavation activities for pilot trenching must always
for Piling Works cable supervised by supervisor
2. Slowly excavate and don’t excavate too deep at once
3. If any underground cable being accidentally
excavated, immediately stop and go far from the area.
4. Supervisor must immediately inform HSE personnel
for further action.
5. Inform SEB and ask for their supervision during pilot
trenching
2. Piling Works and Reinforced Concrete Works

Hazards Safety precaution

Activity

Piling work 1.Sharp object 1. Wear suitable PPE i.e. safety boots, safety
helmet hand glove
2. Falling
object/Sling 2. Not related personal must not go near to piling
parted work area.
3. Unguarded 3. Don’t used damaged wire sling
machineries, tool
and equipment 4. Do not remove machinery safety guard.
4. Swing and hit 5. To do inspection/audit on machinery and
5. Oil leakage equipment weekly/monthly.

6. Vibration/noise 6. ONLY trained and experience operator to

operate machinery.

7. To do maintenance and repair on

weekly/monthly.

8. Wear suitable PPE i.e. ear plug, ear muff

Reinforcement 1. Ergonomics 1. Demonstrate proper body posture/correct

concrete work technique.
2. Pinch point
2. Correct hand placement and wear suitable PPE
3. Concrete i.e. hand glove.
splash
4. Slippery 3. Wear a suitable PPE i.e. safety glasses and
surface safety helmet.

5. Noise from 4. Wear proper PPE i.e. hand glove/safety boots.

concrete vibrator 5. Wear suitable PPE i.e. ear plug, ear muff
4. Water pumping out

Activity Hazards Safety precaution

Pumping out 1. Slip, trip and 1. Slowly go down to trenching/holes during pumping
stagnant water fall out water.
from 2. Electrical 2. Water pump machine must be checked or inspected
excavation hazard before use
trenching or 3. Check if any cut/damage cable/wire of the water pump
hole 4. Adequate PPE must be used during pumping out water.

5. Lifting work

Activity Hazard Safety Precaution

Lifting of 1. Falling object 1. Never walk, stand and work under suspended
pipes using 45 2. Damage/broken load
Tan of Mobile sling 2. Not related workers must not go near to lifting
Crane activities
3. Flagman must be in control if any lifting work
was near to road.
4. Inspect all sling used for lifting work before start
lifting activities.
5. No work shall proceed with broken/damage sling.
6. Proper PPE must be wear.
7. Ensure crane with valid PMA certificate
6. Ensure crane operator competent with DOSH
registration

6. Welding work

Activity Hazard Precaution

Pipe jointing 1. Electrocution 1. Always inspect welding machine part i.e electrode
welding 2. Fumes holder, work piece connection clamp, wire, power
3. Confined space source and etc.
2. Do not do welding work if there was presence of
any stagnant water at the area.
3. Wear proper PPE such as respirator to prevent
excessive inhalation of welding fumes
4. Standby person must be designated for welding
inside the pipe as it was confined space.
4. Provide adequate ventilation during welding
inside the pipe.
6.0 APPENDICES

A. Traffic Management Plan

 Lifting Location

Plastic Barrier

45T Crane
Pipe Bridge

30m
Temporary Road Closed
Signage

ge

30m
Caution Signage