Method Statement For DI Piping

RURAL WATER SUPPLY PROJECT AT
KUARMUNDA AND NUAGAON

DISTT. SUNDERGARH ODISHA
Document No.: MS-PIPING-001/Rev. A Date : 21 -09- 2020

METHOD STATEMENT
STORAGE, HANDLING, TRENCHING, LAYING, INSTALLATION AND

BACKFILLING OF DUCTILE IRON PIPES
A 12-09-2020
Quality Manager Civil Manager Safety Manager Project Manager

Rev. Date
Reviewed By Approved By
A 12-09-2020 Approval
Rev Date Issued for Prepared By Checked By Reviewed By
. No
TABLE OF CONTENTS Page

Page 1
1.0 PURPOSE 3
2.0 SCOPE 3
3.0 REFERENCE DOCUMENTS 3
4.0 MATERIALS SPECIFICATION 3
5.0 DEFINITIONS 4
6.0 ROLES AND RESPONSIBILITIES 4
7.0 PROCEDURES 5
7.1. MATERIALS DELIVERY, STORAGE AND HANDLING 5
7.2. PREPARATORY WORKS 6
7.3. SITE SURVEY 6
7.4. EXCAVATION AND PREPARATION OF TRENCHES 6
7.5. STRINGING OF PIPES 7
7.6 LAYING OF PIPES 8
7.7 JOINT PREPARATION 9
7.8 INSPECTION 12
7.9 HYDRO TESTING 12
7.10 BACK FILLING 13
8.0 MANPOWER REQUIREMENTS 14
9.0 EQUIPMENT REQUIREMENTS 14
10.0 HEALTH AND SAFETY 15
1. PURPOSE
This method statement shall be used for Storage, Handling, Trenching, Laying, Installation And
Backfilling of Ductile Iron Pipes at “ESR for water supply under RWSS scheme in Kuarmunda Block,
Dist. Sundargarh , Odisha.2”.
Page 2
2. SCOPE
This method statement details the procedures for laying and installation of Yard Pipe as well as
Ductile Iron Pipes including excavation, pipe bed preparation and earth filling works at at ESR for
water supply under RWSS scheme in Kuarmunda Block, Dist. Sundargarh , Odisha.2.
3. REFERENCE DOCUMENTS
IS: 12288-(R2007) Code of Practice for Use and Laying of Ductile Iron pipes.
IS: 8329: 2000 Centrifugally Cast (Spun) Ductile Iron Pressure Pipes For Water, Gas And
Sewage.
IS: 9523: 2000 Ductile Iron Fittings for Pressure Pipes for Water, Gas And Sewage
IS: 1196: 1998 Code of Practice for Laying Bitumen Mastic Flooring.
ISO: 8179 Ductile iron pipes, fittings, accessories and their joints — External zinc-based
coating
IS: 5382 Rubber Sealing Rings for Gas Mains, Water Mains and Sewers
IS: 12820: Dimensional Requirements of Rubber Gaskets for Mechanical Joints and Push-on
Joints for Use with Cast Iron Pipes and Fittings for Carrying Water, Gas and Sewage.
IS: 1200 (Part 1) Method of Measurement of Building And civil Engineering Works
CPHEEO manual -1999
Contract Documents (Schedule D, Specification and Standard)
Installation Guide for Ductile Iron Pipe – Ductile Iron Pipe Research Association (2016).
Contract Drawings No.
4. MATERIALS SPECIFICATION
The ductile iron materials shall meet the following requirements:
Material Characteristics Pipes Centrifugally Cast Pipes not Centrifugally Cast,

Fittings, Accessories
Minimum Tensile strength (MPa) 420 420
Minimum elongation at break (%)
DN 40 to 1000 mm 10 05
DN 1100 to 2000 mm 07 05
Page 3
Maximum Brinell hardness (HB) 230 250
5. DEFINITIONS
Client-RWSS, Rural Water Supply and Sanitation Deptt., Odisha
Contractor-Voltas Ltd.
Sub- Contractor Anwesha Engineering and Projects Ltd.
BIS IS - Bureau of Indian Standards
CPHEEO- Central Public Health and Environmental Engineering Organization.
ISO- International Organization for Standardization.
6. ROLES AND RESPONSIBILITIES

6.1 The Site/Construction Manager has overall responsibility for all construction management
activities as well as the implementation of this method statement as well as the compliance of
project specification and approved drawings.
6.2 The QA/QC Manager shall be responsible for all quality related activity.
6.3 The Project/Site Engineer shall be liable for the availability of all type of resources (labor,
material and equipment) to carry out the work as planned.
6.4 The QA/QC Inspector shall be responsible for implementation of this method statement as
well as other QA/QC activities while executing all the associated works.
6.5 The Project Engineer/Supervisor/Safety Manager/Officer shall be responsible to ensure that

all safety precautions are in place, and that all personnel are using the required personal protective
equipment. He must also ensure that all relevant permissions are available for the works.
7. PROCEDURES
7.1 MATERIALS DELIVERY, STORAGE AND HANDLING

7.1.1 All of the materials and equipment shall be stored / preserved in accordance with the
Vendor’s / Manufacturers recommendations, requirements, technical specifications and suggestions.
Page 4
7.1.2 During Off-Loading Cranes should be preferred for off-loading. However, for pipes up to 400
mm nominal bore, skid timbers and ropes may be used.
7.1.3 When using mechanical handling equipment, it is necessary to employ sufficient personnel to
carry out the operation efficiently with safety.
7.1.4 In case of conflict between the Vendor/Manufacturer’s recommendations and the

requirements of this document or Company documents, Vendor/Manufacturer’s recommendations
shall be adopted.
7.1.5 All equipment shipped with protective covers or plugs on openings, and with rust preventive
coatings applied on exterior machined and threaded surfaces, shall be treated as follows on arrival at
the Site:
● Protective covers, plugs shall be replaced if damaged.
● If water or dirt has entered the equipment through damaged or improperly secured
covers and plugs, the equipment shall be cleaned before covers, plugs and coatings are put
back into their former position.
● The Material Controller is responsible for inspecting the consignment for any visible
damages and quantity check to confirm the compliance with the Purchase Order (PO)
quantity (wherever applicable).
7.1.6 Pipes are to be inspected at site to see any damage to the pipe including lining or outside
coating has occurred during transportation and chandelling. Any damage (material, coating, lining
etc) in receiving material, shall be separated and informed to the concern authority before its use.
7.1.7 Pipes being taken to a stock ground for storage and held pending further distribution should be
arranged into stacks. The first layer of pipes should be laid on a firm foundation consisting of solid
timbers set level on the ground. Subsequent layers should be placed according to the method of
stacking adopted. Care should be taken so that the pipes do not rest on their sockets. The height of
any stack should not exceed 12 ft.
7.1.8 Pipe stock may be Square Stacking, Parallel Stacking with Timbers, Nested Stacking (Pyramid
Stacking)
7.1.9 Bitumen-sheathed pipes should be handled with care to avoid any damage to the sheathing.
They should not be stacked but laid in a single layer supported on timbers placed under the uncoated
portions of the spigots and sockets.
7.1.10 Documents related to materials issue shall be maintained by the material controller till the
end of the project.
Page 5
7.2 PREPARATORY WORKS

Prior to starting of work, the followings shall be checked:
7.2.1 Approval of Method Statement.
7.2.2 All the required engineering drawings and documents are approved and received in time.
7.2.3 All tools, equipment and temporary items are ready in sufficient quantities and calibrated.
7.2.4 Preliminary work required to be done before laying of pipelines includes pegging out, clearing
and disposal of all shrubs, grasses, large and small bushes, trees, hedges, fences, gates,
portions of old masonry, boulders, and debris from the route.
7.2.5 Written instructions should be obtained from the Contractor/ Contractor representative for
the destruction, removal, or preservation of trees, shrubs, lawns, and fences along the
pipeline.
7.3 SITE SURVEY

7.3.1 The choice of route for a pipeline is governed by economic considerations and other factors
such as overhead and underground cables, existing pipelines and traffic flow.
7.3.2 Field surveys for strip width representing about 500 m along the proposed alignments should
be carried out.
7.3.3 Any vertical section or profile along the pipeline route should be shown to a scale appropriate
to the variations in ground elevation.
7.3.4 Any Special crossings which require permission from authority should places.
7.4 EXCAVATION AND PREPARATION OF TRENCHES

7.4.1 Trenching includes all excavation which is carried out manually or by machine. The trench
shall be so dug that the pipe is laid to the required depth at required alignment.
7.4.2 The width of the trench at bottom between the faces of sheeting shall be such as to provide
not less than 200 mm clearance on either side of the pipe except where rock excavation is involved.
7.4.3 In agricultural land, the depth should not less than 900 mm so that the pipeline will not
interfere with the cultivation of the land.
7.4.4 Blasting for Rock Excavation shall be permitted only after the approval of the authority and
only when proper precautions are taken for the protection of persons and property. The hours of
blasting shall be fixed by the authority.
7.4.5 Open-cut trenches shall be done with the direction of contractor or governing state laws /
municipal regulations which may necessary to protect life
Page 6
7.4.6 Public safety considerations, safety precautions must be observed by personnel at the job
site. The need for shoring depends on the nature of the soil and depth of the trench.
7.4.7 Care should be taken to avoid the spoil bank causing an accumulation of rainwater.
7.4.8 Suggested trench with as billow.
7.5 STRINGING OF PIPES

7.5.1 Stringing consists of placing pipes on the ground in line ready for laying. Care should be taken
to prevent damage during this operation.
7.5.2 Pipe may be moved a short distance at the work site, as from one side of the street to the
other, should be rolled by hand or lifted and moved by machine. It should not be pushed or dragged.
7.6 LAYING OF PIPES

7.6.1 Before any length of pipe is lowered into the trench, it should be inspected for damage. All
construction debris should be cleared from the inside of the pipe either before or just after a joint is
Page 7
made. This is done by passing a pull-through in the pipe, or by hand, depending on the size of the
pipe.
7.6.2 Pipes should be lowered into the trench with equipment suitable for the weight of pipes. For
smaller sizes, up to 250 mm nominal bore, the pipe may be lowered by the use of ropes but for
heavier pipes, either a well designed set of shear legs or mobile crane should be used.
7.6.3 If a cable sling is used around the centre of the pipe, a wooden block placed between the
pipe and the cable will reduce the likelihood of pipe slippage.
7.6.4 On slope of 1 : 15 or steeper, precautions should be taken to ensure that the spigot of the
pipe being laid does not move into or out of the socket of the laid pipe during the jointing operations.
7.6.5 During Above Ground Laying - The ground should be dressed to match the curvature of the
pipe shell for an arch length subtending an angle of 120” at the centre of the pipes. Alternatively, the
pipeline should be laid either on saddle, roller or rocker supports as specified by authority. The pipes
may be allowed to rest on ground if the soil is non-aggressive.
7.6.6 Where pipes are to be bedded directly on the bottom of the trench (See Fig. IA), Where
excavation is through rocks or boulders, the pipeline should be bedded on concrete bedding ( see Fig.
1B ) or on at least 150 mm of fine grained material ( see Fig. 1C ), or other means are used to protect
the pipe and its coating.
7.7 JOINT PREPARATION

7.7.1 Procedure for jointing will vary according to the type of joint being used. Basic requirements
for all types are:
Page 8
a) Cleanliness of all parts,
b) Correct location of components,
c) Centralization of spigot within socket, and
d) Strict compliance with manufacturer’s jointing instructions.
7.7.2 Two main types of joints are used with ductile iron pipes and fittings: a) Socket and spigot
flexible which is divided push on joints and Mechanical joints b) Rigid flanged joint.
7.7.3 The spigot and socket flexible joint should be designed to permit angular deflection in
direction and axial movement to compensate for ground movement and thermal expansion and
contraction.
7.7.4 Both push-in and mechanical joints are flexible joints. Flexible joints require to be externally
anchored at all changes in direction such as at bends, etc, and at blank end to resist the thrust
created by internal pressure and to prevent the withdrawal of spigots.
7.7.5 Flanged joints are made on pipes having a machined flange at each end of the pipe. The seal
is usually affected by means of a flat rubber gasket compressed between two flanges by means of
bolts which also serve to connect the pipe rigidly.
7.7.6 The inside of sockets and the outside of spigots should be cleaned and wire brushed for a
distance of 150 to 225 mm. Glands and gaskets should be wiped clean and inspected for damage.
When lifting gear is used to place the pipe in the trench, it should also be used to assist in centralizing
the spigot in the socket
7.7.7 Where the pipeline is likely to be subjected to movement due to temperature variations, the
use of flexible joints is recommended. A gap should be left between the end of the spigot and the
back of the socket.
7.7.8 The push-on joint consists of a special bell, plain end, and rubber gasket. The bell is provided
with an internal groove in which the appropriate gasket is seated. The plain end is bevelled, and the
joint is assembled by pushing the plain end into the bell, which compresses the gasket and forms a
watertight seal.
7.7.9 Care must be exercised that the correct gasket is being used for the joint being installed and
that the gasket faces the proper direction.
7.7.10 When pipe is cut in the field, bevel the plain end with a heavy file, an air-driven grinder, or
other suitable device and remove all sharp edges.
7.7.11 The type of cutting wheel used for cast iron pipes may not suitable for ductile iron pipe.
Special wheels, as used for cutting steel pipes, shall be used and cut ends are trimmed with a file
Page 9
7.7.12 Mechanical joints, push-on joints and gaskets shall conform to the requirements of ISO 9523.
7.7.13 In cold weather, it may be necessary to warm the gasket to facilitate insertion.
7.7.14 Push-On Joint Assembly as sequence as bellow..
(1)Thoroughly clean & Using (2)Apply lubricant to the exposed surface of

gasket of the proper design the gasket and plain end of the pipe or fitting
(3)Push the plain end into the bell socket

(4) pipe can be pushed into the bell keeping the joint
straight while pushing. socket with a long bar
7.7.15 Mechanical-Joint Assembly
(1) Wipe clean the bell recess and the (2) Insert the plain end into the socket
plain end. and press the gasket
Page
10
(3) Push the gland toward the socket (4) Tighten the bolts
7.7.16 Pipeline should be securely anchored at dead ends, tees, bends, tapers and valves to resist
thrust arising from internal pressure.
Page
11
7.7.17 Maximum Deflection Full Length Pipe Push-on Joint may permit angular deflection to
accommodate ground movements and negotiate large radius bends. The angle deflection shall be as
per the table below:
5 ° for DN 80 to 300
3° for DN 350 to 1600
7.8 INSPECTION
7.8.1 All pipe delivered to the job site shall be clearly marked at the factory with size, type, class of
pipe, lot number, date of manufacture and manufacturers identification. Additional markings, as
required, shall also be included.
7.8.2 All pipe, and fittings shall be carefully inspected for defects immediately prior to laying. No
cracked, broken or defective materials shall be used in the work. If any defective piece shall be
discovered after having been laid, it shall be removed and replaced with a sound one in an acceptable
manner.
7.8.3 Inspection records shall be properly recorded and maintained with proper identification for
each joint.
7.8.4 Inspection shall be carried out as per approved procedure and the results shall be recorded
properly.
7.9 HYDRO TESTING

7.9.1 The completed pipeline may be tested either in one length or in sections; the length of
section depending upon :
1) Availability of suitable water,
2) Number of joints to be inspected, and
3) Difference in elevation between one part of the pipeline and another-
7.9.2 Where the joints are left uncovered, sufficient material should be backfilled over the centre of
each pipe to prevent movement under the test pressure. The field test pressures are applied to
ductile iron pipelines only when the pipeline and its fittings are properly anchored.
7.9.3 Lengths of about 1.5 km or more, are tested in one section, subject to consideration of length
of trench which can be left open in particular circumstances.
7.9.4 Each section should be properly sealed-off, preferably with special stop ends secured by
adequate temporary anchors. The thrust on the stop ends should be calculated and the anchors
designed to resist it. All permanent anchors should be in position and, if of concrete, should have
Page
12
developed adequate strength before testing begins. The section under test should be filled with
water, taking care that all the air is displaced either through vents.
7.9.5 After filling, the pipeline should be pressurized to the specified operating pressure and left for
a period of time to achieve stable conditions.
7.9.6 The pipeline is pressurized up to the full test pressure and the section under test completely
closed off. The test should be maintained for a period of not less than 10 minutes to reveal any
defects in the pipes, joints or anchorages.
7.9.7 The test pressure should be measured at the lowest point of the section under test or
alternatively, an allowance should be made for the static head between the lowest point and the
point of measurement, to ensure that the required test pressure is not exceeded at the lowest point.
7.9.8 Methods employed for finding leaks include:
1. Visual inspection of each joint if, not covered by the backfill;
2. Use of a bar probe to detect signs of water in the vicinity of joints, if backfilled;
3. Use of electronic device which detects and sound or vibrations due to escaping of
water, actual contact between the probe and the pipe is not essential;
4. Injection of a dye into the test water-particularly suitable in water-logged ground; and
Introduction of nitrous oxide in solution into the test water and using an infra-red gas
concentration indicator to detect the presence of any nitrous oxide that has escaped through
the leak.
7.9.9 If the test is not satisfactory, the fault should be found and rectified. Where there is difficulty
in locating a fault, the section under test should be sub-divided and each part tested separately.
7.9.10 After all sections have been joined together on completion of section testing; a test on the
complete pipeline should be carried out. This test should be carried out at a pressure not less than
the maximum sustained operating pressure or the maximum static pressure of the pipeline and,
during the test, inspection made of all work which has not been subject to section tests. During the
test, the pressure at the lowest point in the pipeline should not exceed the maximum given in IS-
12288-(R2007) Table 1.
7.10 BACK FILLING

7.10.1 For the purpose of backfilling, the depth of the trench shall be considered as divided into the
following three zones
a) Zone A: From the bottom of the trench to the level of the centre line of the pipe,
Page
13
b) Zone B :From the level of the centre line of the pipe to a level 300 mm above the top of the
pipe,
c) Zone C: From a level 300 mm above the top of the pipe to the top of the trench.
7.10.2 Back-Fill Material shall be free from residue, ashes, slag, refuse, rubbish, vegetable or organic
material, lumpy or frozen material, boulders, rocks or stone or other material, which in the opinion of
the authority, is unsuitable or deleterious. However, material containing stones up to 200 mm as
their greatest dimension may be used in Zone C, unless specified otherwise herein.
7.10.3 Sand used for back-fill shall be natural sand complying with fine to coarse. The total weight of
loam and clay in it shall not exceed 10 percent. All material shall pass through a sieve or aperture size
2.00 mm and not more than 5 percent shall remain on IS Sieve or aperture size 0.63 mm.
7.10.4 Gravel used for back-fill shall be natural gravel, and having durable particles graded from fine
to coarse in a reasonably uniform combination with no boulders or stones larger than 50 mm in size.
It shall not contain excessive amount of loam and clay and not more than 15 percent shall remain on
a sieve of aperture size 75 micron.
7.10.5 Backfilling shall not be done in freezing weather except by permission of the authority,
7.10.6 Back-filling in Zone A shall be done with sand, fine gravel or other approved material placed in
layers of 150 mm and compacted by tamping.
7.10.7 Back-filling in Zone B & Zone C shall be done by hand or approved mechanical methods in
layers of 150 mm, special care being taken to avoid injuring or moving the pipe. The type of backfill
material to be used and the method of placing and consolidating shall be prescribed by the authority.
7.10.8 The excavated material may be used for backfill in the following cases,
a) In Zone C, in cases where settlement is unimportant and when shown on the drawings or
specified, the back-fill shall be neatly rounded over the trench to a sufficient height to allow
for settlement to the required level.
b) In any zone, when the type of back-fill material is not indicated or specified, provided that
such material consists of loam, clay, sand, fine gravel or other materials which are suitable for
backfilling in the opinion of the authority.
8. MANPOWER REQUIREMENTS
a. Site Engineer
b. Inspector
c. Technicians
Page
14
d. Labour / Helpers
9. TOOLS & EQUIPMENT REQUIREMENTS

Personal Protective Equipment
Gum Boot
Measuring and Levelling Tools
Moveable scaffold
Ladder
Hand Tools/ Tools.
Drill Machine
Hammer
Cutter
Measuring Tape
Tool Box
10. HEALTH AND SAFETY

10.1 HSE Manager shall ensure that the work is performed accordance to the approved
Construction Safety Manual and precautions specified in the work permit. He shall ensure that
barricades, warning tapes, warning signs, fire fighting equipment and first aid kits are readily
available at the working area.
10.2 All materials, piles equipment and pipes which may serve as obstruction to traffic shall be
enclosed by fences or barricades and shall be protected by illuminating proper lights when the
visibility is poor. The rules and regulations of the local authorities
10.3 Tool box talk shall be conducted on a daily basis to inform the workers of the recent safety
issues and incidents and to get feedback of any unreported unsafe acts.
10.4 The work shall be carried including closing of road/street in such a manner which will cause
the least interruption to traffic.
10.5 Area shall be barricaded adequately with warning barriers prior to any lift.
10.6 Unauthorized persons shall be excluded from the area.
10.7 Adequate caution boards and warning signs shall be provided.

Page
15
10.8 On completion of job, the area shall be cleared of any materials and keep clean and tidy.
10.9 Hazard analysis for hazardous operation shall be carried out prior to commencing the works.
Page
16

Method Statement For DI Piping

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Method Statement For DI Piping

Uploaded by

Copyright:

Available Formats

RURAL WATER SUPPLY PROJECT AT

KUARMUNDA AND NUAGAON

Document No.: MS-PIPING-001/Rev. A Date : 21 -09- 2020

STORAGE, HANDLING, TRENCHING, LAYING, INSTALLATION AND

Quality Manager Civil Manager Safety Manager Project Manager

TABLE OF CONTENTS Page

3.0 REFERENCE DOCUMENTS 3

4.0 MATERIALS SPECIFICATION 3

6.0 ROLES AND RESPONSIBILITIES 4

7.1. MATERIALS DELIVERY, STORAGE AND HANDLING 5

7.2. PREPARATORY WORKS 6

7.3. SITE SURVEY 6

7.4. EXCAVATION AND PREPARATION OF TRENCHES 6

7.5. STRINGING OF PIPES 7

7.6 LAYING OF PIPES 8

7.7 JOINT PREPARATION 9

7.9 HYDRO TESTING 12

7.10 BACK FILLING 13

8.0 MANPOWER REQUIREMENTS 14

9.0 EQUIPMENT REQUIREMENTS 14

10.0 HEALTH AND SAFETY 15

CPHEEO manual -1999

Contract Documents (Schedule D, Specification and Standard)

Contract Drawings No.

The ductile iron materials shall meet the following requirements:

Material Characteristics Pipes Centrifugally Cast Pipes not Centrifugally Cast,

Maximum Brinell hardness (HB) 230 250

Sub- Contractor Anwesha Engineering and Projects Ltd.

BIS IS - Bureau of Indian Standards

CPHEEO- Central Public Health and Environmental Engineering Organization.

ISO- International Organization for Standardization.

6. ROLES AND RESPONSIBILITIES

6.5 The Project Engineer/Supervisor/Safety Manager/Officer shall be responsible to ensure that

7.1 MATERIALS DELIVERY, STORAGE AND HANDLING

7.1.4 In case of conflict between the Vendor/Manufacturer’s recommendations and the

● Protective covers, plugs shall be replaced if damaged.

7.2 PREPARATORY WORKS

7.2.1 Approval of Method Statement.

7.3 SITE SURVEY

7.4 EXCAVATION AND PREPARATION OF TRENCHES

7.4.8 Suggested trench with as billow.

7.5 STRINGING OF PIPES

7.6 LAYING OF PIPES

7.7 JOINT PREPARATION

a) Cleanliness of all parts,

b) Correct location of components,

c) Centralization of spigot within socket, and

d) Strict compliance with manufacturer’s jointing instructions.

7.7.14 Push-On Joint Assembly as sequence as bellow..

(1)Thoroughly clean & Using (2)Apply lubricant to the exposed surface of

(3)Push the plain end into the bell socket

7.7.15 Mechanical-Joint Assembly

3° for DN 350 to 1600

7.9 HYDRO TESTING

1) Availability of suitable water,

2) Number of joints to be inspected, and

3) Difference in elevation between one part of the pipeline and another-

7.9.8 Methods employed for finding leaks include:

1. Visual inspection of each joint if, not covered by the backfill;

7.10 BACK FILLING

9. TOOLS & EQUIPMENT REQUIREMENTS

Measuring and Levelling Tools