PROJECT

CGK 063

METHOD STATEMENT OF MECHANICAL WORK FOR

DOCUMENT
SOILS & WASTE WATER UNDERGROUND
TITLE
PIPE INSTALLATION
Contents

1.0 PURPOSE.......................................................................................................................................................
2.0 SCOPE OF WORK...........................................................................................................................................
3.0 DEFINATIONS................................................................................................................................................
4.0 REFERENCE....................................................................................................................................................
5.0 RESPONSIBILITIES.........................................................................................................................................
6.0 PROCEDURE..................................................................................................................................................
6.1 General Description...............................................................................................................................
6.2 Material..................................................................................................................................................
6.3 Plants, Machinery & Equipment............................................................................................................
6.4 Manpower..............................................................................................................................................
7.0 INSTALLATION UPVC & DICL PIPE PROCEDURES.........................................................................................
7.1 General Guidelines.................................................................................................................................
7.1.1 Pre-Planning Stage..................................................................................................................
7.2 The Process Installation Stage...............................................................................................................
7.2.1 uPVC & Fitting Storage at Site.................................................................................................
7.2.2 uPVC Installation Procedure...................................................................................................
7.2.3 Pipe in Sleeve (Wall)................................................................................................................
7.2.4 Pipe in Slab..............................................................................................................................
7.2.5 DICL Installation Procedure.....................................................................................................
7.2.6 Jointing for uPVC o DICL pipe..................................................................................................
7.2.7 Pipe Leakage Test....................................................................................................................
8.0 APPENDICES..................................................................................................................................................
8.1 Drawing..................................................................................................................................................
As Attached Drawing.............................................................................................................................
8.2 RISK ASSESSMENT (RA)..........................................................................................................................
8.3 INSPECTION TEST PLAN (ITP).................................................................................................................
8.3.1 CGK063-ITP-RFSI - Request for Site Inspection...............................................................................
8.3.2 CGK063-ITP-M.03 - Site General Report..........................................................................................
8.3.3 CGK063-ITP-M.04 - Site Defect Inspection Report..........................................................................
8.3.4 CGK063-ITP-M.01 - Floor Opening/ Pipa Sleeve Inspection Sheet .................................................
8.3.5 CGK063-ITP-M.40 - Drainage & Sewerage Pipe Water Leakage Test .............................................
8.3.6 CGK063-ITP-M.13 - Piping Installation Checklist.............................................................................
8.3.7 CGK063-ITP-M.33 - Undergroung Piping Inspection Test Report...................................................
8.3.8 CGK063-ITP-M.43 – Internal Drainage Flow Inspection Test Report..............................................
1.0 PURPOSE
The purpose of this statement is to document the correct procedure and installation of
soils & waste water underground pipe installation for CGK 063 project, and to ensure
that all concerned are familiar with the sequence of activities, utilization of resources
and execution of the works in compliance with applicable safety, quality procedures
and project documents and specification.

2.0 SCOPE OF WORK

This method statement is the necessary measures to ensure that all installation
activities to be identified and established and approved by the Employer’s
representative. All activities will be carried out in accordance with the contract details
and in full compliance to the contract specifications will be done in compliance with
requirements issued by authorities. The scope of this plan is to provide a guideline for
the implementation of quality assurance on installation work soils & waste water
underground pipe installation.

3.0 DEFINATIONS
Terms Definition
Project CGK 063
JO PT Jaya Obayashi
MOS Method of Statement
MSA Material Submission Approval

Table 1: Definitions

4.0 REFERENCE
The following Standards of Practice shall be applicable to the works:
 SNI 8153:2015 : System plumbing pada bangunan Gedung (Plumbing
System in Building).
 SNI 7511:2011 : The Procedure for Installing Transmission Pipes and
Distribution Pipes and Pipe Crossing Buildings.
  SNI 03-1745-2000 : Concerning procedures for planning and installing vertical
pipe systems and hoses for the prevention of fire hazards in
buildings
 BS 3974-2 : Specification Pipe Support, Pipe Clamps, Cages, Cantilevers &
Attachment to beams.
 BSEN 545 : Ductile Iron Pipe, Fittings, Accessories and their joints for
water pipelines

5.0 RESPONSIBILITIES
No Designation
.
1 Project Manager
2 M&E Engineer
3 QA / QC Engineer
4 Safety Officer
5 Supervisor
Qty Responsibility
1 Responsible for overall commercial, contractual
& technical performances associated with
specific project. Reporting to the Project
Director.
4 Planning and supervising installation activities.
2 Inspect, verify, and prepare work statement for a
quality installation works. Material storage, fit
for use tools and equipment, and installation
works
1 To provide toolbox and guidance to work and to
ensure that work is carried out in a safe manner.
3-5 Obtain permit to work, control the sequence
according to MOS, approved shop drawings, and
MSA, ensure mechanical aspects of the work are
according to the specifications, ensure safe
practices are followed and ensure quality of
workmanships during execution. Ensure material
temporary storage and protection meet vendor
and standards requirement
 No Designation Qty Responsibility
.
. Ensure tools being used for installation are
calibrated and meet vendor and standards
requirement
6 General Workers 10-15 To carry out all the mechanical aspects of soil &
waste water pipe underground installation.

Table 2: List of Responsibilities

6.0 PROCEDURE
6.1 General Description
The mechanical work for underground soils & waste water pipe installation to
be carried out in the CGK063 project.

6.2 Material
Materials are as below:

Ite Descriptions Purpose

m
1 uPVC Pipe Waste pipe connection from fitment to floor traps.
Waste water pipe between inspection chamber to
2 DICL pipe inspection chamber, inclusive of below roads and
underneath the buildings.

Table 3: List of Materials

6.3 Plants, Machinery & Equipment

Item Descriptions

1 Pipe cutters/ hacksaw/ cutting wall

2 Paint brush
3 Sandpaper
4 Soft cloth
5 Pipe glue
6 Pencil / marker
 Item Descriptions
7 Measuring tape
11 Spanners &Torque wrench
12 Clamps, Jointing Tackles, trimmers & heater plate
13 Thread machine
14 Weld machine

Table 4: List of Plants, Machinery and Equipment

6.4 Manpower
The actual manpower of each type of installation may vary according to the site
condition and requirement.

All workers shall wear appropriate PPE (Hard Hat, Protective Boots, Goggles,
High Visibility Vest and Protective Gloves) and safety harness when working
above 2 meter in height.

7.0 INSTALLATION UPVC & DICL PIPE PROCEDURES

7.1 General Guidelines
7.1.1 Pre-Planning Stage
 Secure all necessary design information and prepare all the necessary
designed drawings.
 Submission of design drawings for approval.
 Prepare all necessary shop drawings and determine the actual position to
commence installation with the mobilization of required work force, tools
and equipment.
 Prepare all documents required in Specification submittals and all
documents/certification required in Specification.
  Prepare material approval document, complete with confirmation of
conformance between delivered material with approved material
(code/model/type, length, weight, width, materials, quantity, etc).
 Prepare confirmation of conformance between temporary storage and
vendor storage requirement/standard.
 Prepare confirmation of conformance between tools and its calibration
meet vendor requirement/standard.
 Ensure all approval required to perform work are obtained and conform
with approved documents by consultant Engineers and Architect.

7.2 The Process Installation Stage

7.2.1 uPVC & Fitting storage at site

Material Storage at Site (comply to SNI 7511-2011/Procedure for
Storage and Installation PVC Pipe).
Generally, the pipes and fittings must be stored away from
excessive heat, avoid contamination by oils, petrol or greases.

For temporary storage on site, the ground should be level and free
from stones or sharp objects likely to damage the pipe. Carefully store
pipe in tapered stacks or cross stacks not more than 1 meter high.

It is important that each pipe should have an even bearing throughout

its entire barrel length. Pipes of different sizes should be stacked
separately. Where this is not possible, larger diameter pipes should be
placed at the bottom.
 Picture 1: Pipe storage procedures in the site

Ensure pipes are not kept along access route and free from rubbish
and debris. Pipes must be stacked properly in a dry area and covered
until required for installation. Ensure pipes size and material used
comply to approved shop drawing and according to coordinated
routing. Ensure internal surface of pipes are clean. CGK063 project for
underground pipe installation plumbing works, air vent, sanitary
fixture installation pipe, waste installation & drain for air conditioning
installation.

7.2.2 Installation Procedure (comply to SNI 7511-2011/Procedure for

Storage and Installation PVC Pipe) 
 Prepare approved materials, namely uPVC pipes, adhesive
solvents and connection tools. Check the area according to the
approved drawing.
 Excavate the pipe trench routing and level setting as marked on
site which shall check & comply according to approved shop
drawing. Should there be any discrepancy, immediate site report
shall feedback to site engineer in change

Picture 2: The excavator underground pipe line & check the level pipe installation

 After the excavation and check the level of the soil is complete,
Instal ground based for pipe installation with concrete and fill
separated part with sand.

Picture 3: The Based for pipe installation

 Mark the pipe following the depth of the socket, then clean the
inside of the socket and pipe then coat it lubricant with adhesive.
 Picture 4: Marking the pipe

Picture 5: Cleaning inside of the socket

Picture 6: Lubricant with adhesive process

 Joint Position the pipes correctly, then connect the pipes until
they connect according to the marking. If the pipe size is more
than  4, join the pipe with the tackle.
 Picture 7: Jointing pipe uPVC process

 Install pipe and check again pipe level.

Picture 8: Install pipe, check level Pipe

  Then backfilling with sand one layer of sand approximately 100m
on top of pipe.

Picture 9: Backfilling Pipe Process

 Leakage test pipe, for indicating leakage marking top of water at

the lowest level stand pipe. After test, back filled and finish the
remaining height of the pipe trench will be backfilled with soil
after compaction.

7.2.3 Pipe Sleeve (Wall)

 Before installing pipe sleeves, it would be better if we first make
sure the image has been agreed between architect and ME.
 Checking M&E drawings as compared to Architect’s.
 Any discrepancies to be highlighted to Client before the pipe
sleeve being installed.
 Upon finalization of above matter, monitor the formwork and
steel work at site.
 Check level for sleeve install position, use theodolite
 Picture 10: Check level sleeve install position

 Check position or distance point based on design drawing and

make mask at reinforcement.

Picture 11: Check position or distance point

 Install sleeve at civil reinforcement

Picture 12: Install pipe sleeve

 Install R-Bar reinforcement for sleeve protection (civil In Charge) &
marking the formwork for sleeve, and make sure the distance and
make hole at formwork

Picture 13: Install R-bar & marking the formwork for sleeve

 After formwork is ready, position of all necessary pipe

sleeves will be marked on the formwork. Install and secure marker
plate on formwork. Cover Sleeve with styrofoam and seal tape.
 Inspection of pipe sleeves must be carried out in the
representative of consultant and other relevant parties to ensure
the position of sleeve install is accordingly to the requirement.
 After approval, casting will be carried out by main contractor.
Upon casting work done, the sleeves will be re- checked for
locations as against brick wall partition to ensure all sleeves
installed are as per setting.
 Picture 14. Detail drawing Pipe Sleeve wall

Slope will be 1:100 for pipe size DN80 mm and above. Slope will be
1:50 for pipe size DN80 mm and below. Slope will be 1:100 for all Vent
Pipe. uPVC pipe connection to sanitary fixtures, vent pipes and
inspection chambers shall follow approved shop drawing.

7.2.4 Pipe in slab

 Before installing pipe in slab, it would be better if we first make
sure the image has been agreed between structure, architect and
ME.
 Check the pipe point to be installed in accordance with the
approved drawing, then take measurements according to the
point.
 Make iron fabrications for replacement in accordance with the
approved field sizes and drawings.
 Install the hanger on the floor plate iron, attach the hanger bolts
by bending it with concrete and tie it with an iron rod firmly.
Picture 15. Support hanger underground pipe installation
Picture 16. Piping arrangement for floor trap (p-type) & water closet pan connecting in series

Picture 17. Typical detail of waste for connection basin and floor trap connection
7.2.5 DICL Installation Procedure
Installation Procedure for assembly of push on joint (Comply to SNI
19-6782-2002/Procedure for Storage and Installation Iron Ductile
Pipe).
 Jointing Instruction
Before assembling the joint, the spigot of the pipe and interior of
socket of the adjacent pipe should both be thoroughly cleaned.

Picture 18. Process Cleaning Spigot & socket

 Insertion of Gasket
The gasket should be wiped clean, flexed and then placed in the
socket with pipa leading. The groove in the gasket must be located
on the retaining bead in the socket, and the retaining heel of the
gasket firmly bedded in its seat. Ensure the gasket fits evenly
around the whole circumference, removing any bulges that
prevents the proper entry of the spigot end.
 Picture 19. Sequence of installation for gasket

 Process Lubrication
A thin film of lubricant is applied to the inside surface of the
gasket which will be in contact with the entering spigot. In
addition, a thin film of lubricant should be applied to the
outside surface of the spigot end.

Picture 20. Application of lubrication

 Initial Entry of Spigot
The spigot of the pipe being jointed must be aligned and entered
carefully into the adjacent socket until it makes contact with the
gasket. Final assembly of the joint is completed from this position.

Picture 21. Initial entry of spigot

 Stop the installation immediately if too much resistance is found

during inserting the ductile iron pipe. Pull out the pipe and check
location of the gasket, the socket and the spigot of the pipe,
identify the causes and handle them properly before re-
installation.
 Complete Assembled Joint
Joint assembly is completed by forcing the spigot end of the
entering pipe past the gasket, which is thus compressed, until the
first painted strip on the end of the pipe disappeared and the
second painted striped is approximately flushed with the socket
face.
 If joint is difficult to assemble, the spigot should be removed and
rotated 90◦ before attempting to assemble a second time.
If the joint is still difficult to assemble, the spigot should be
removed and the gasket to be examined. Final gradient and slope
of pipe shall be as per approved shop drawing.

Picture 22. Complete Assembled Joint

 Concrete support
Before the concrete haunching is carried out, the underground
pipe must be installed with a concrete support/ saddle block. The
details are in accordance with the approved shop drawing.

Picture 23. Underground Saddle Block Pipe/ concrete support

 Concrete Haunching Detail

 Underground pipes shall be complete with bedding and concrete
haunching. Details to be as per approved shop drawings.

Picture 24. Detail Concrete haunching for underground pipe

7.2.6 Jointing for uPVC to DICL pipe

 Here we explain the steps for connecting PVC and DICL pipe
installations using the flange connection technique:
 Cut the pipe according to the size in the field and then clean
both ends of the pipe to be connected, either uPVC or DICL
pipes.
 Thoroughly clean the surface of the flanges to be used for
joining, making sure that there are no dirt, foreign matter
particles, protrusions, or build-up of coating on the surface of
the pair.
 Use a scraper or wire brush to remove any dirt or build-up on
the surface of the pair.
 Cut the pipe according to the size in the field and then clean
both ends of the pipe to be connected, either uPVC or DICL
pipes.
 Thoroughly clean the surface of the flanges to be used for
joining, making sure that there are no dirt, foreign matter
particles, protrusions, or build-up of coating on the surface of
the pair.
 Use a scraper or wire brush to remove any dirt or build-up on
the surface of the pair.
 Ensure that the mating threads of all nuts and bolts are clean
and in good condition and fit.
 Position the two pipes between the uPVC and DICL pipes that
have the same flange attached to the end of the pipe with the
gasket, so that the gasket is snugly in the middle between the
two flanges.
 Slide the gasket into the gap between the flanges, then install
all the bolts, and adjust their position with a rubber bend.
 Lubricated the bolts. Be sure to lubricated bolts, nuts and
washers fall bearing surfaces. Evenly apply a suitable lubricant
to all mating threads, including the nut load bearing face.

 Align the flanges to be joined and ensure that the components

are satisfactorily supported to avoid bending stress on the
flanged joint during and after assembly.
 Assemble bolts, washers and nuts on the flange. Tightening
bolts follow one direction. Preferably using a torque wrench
for required torque.

 Offer the adjoining flange to the bolts, taking care to maintain

alignment and support of the components. Check alignment of
 flange faces and gasket. Insert the remaining bolts and tighten
nuts to finger tight.

 Tighten nuts to 30% of estimated torque. Then tighten to 60%

of estimated torque using the same tightening sequence.

 Tighten to 100% of estimated torque using the same

tightening sequence.

 Finish with one final pass, torquing in a clockwise direction, or

until all fasteners are torqued evenly.

Picture 25. Before Jointing pipe uPVC to DICL pipe

Picture 26. After Jointing pipe uPVC to DICL pipe

7.2.7 Pipa Leakage Test
Piping Installation shall be tested before being closed, all possible
leaks in joint shall be re-tested. See method and drawing follow
below:

 Plug low end of pipe main line by ball plug (see drawing detail how
to test - ball plug setting).
 Pour the water into other side of the pipe main line and ensure
water visible at the top end of all branch line.
 Mark inside pipe as water level indicator by pen and put the ball
on the water.
 Check all connection and joints, after 30 minutes of holding.
 Check water level which marked, if water level condition below
the indicator mark it is leak.
 All leaks shall be repaired after draining of water by removal and
replacement of detective part.
 Test shall be repeated after repaired.
 Test is acceptable when no leaks are found.
 Remove the test ball and draining the water.

Picture 27: Leakage Test Installation by ball plug (Indoor Area)

 Picture 28: Pipe Leakage Test Installation by ball plug (Outdoor Area)

Picture 29: Jointing Test Ball Plug Hose & Air Pump

 Water Flow Test

 Non-pressurised pipes shall undergo water flow test to ensure
required gradient flow is achieved.
 Clear all obstructing debris in the pipeline.
 Insert a ping pong ball at the high end of the pipe and pour in the
water.
 The test is considered passed when the ball rolls out at the lower
end of the pipe.
8.0 APPENDICES
8.1 DRAWING
As attached drawing

8.2 RISK ASSESSMENT (RA)

8.3 INSPECTION TEST PLAN (ITP)

8.3.1 CGK063-ITP-RFSI - Request for Site Inspection

8.3.2 CGK063-ITP-M.03 - Site General Report

8.3.3 CGK063-ITP-M.04 - Site Defect Inspection Report

8.3.4 CGK063-ITP-M.01 - Floor opening/ Pipe Sleeve Inspection Sheet

8.3.5 CGK063-ITP-M.40 - Drainage & Sewerage Pipe Water Leakage Test

8.3.6 CGK063-ITP-M.13 - Piping Installation Checklist

8.3.7 CGK063-ITP-M.33 - Underground Piping Inspection Test Report

8.3.8 CGK063-ITP-M.43 - Internal Drainage Flow Inspection Test Report