Method Statement For Underground Piping & Puddles Installation

Doc No.
7200040907-JWWF-GC-060 Rev 00
PROJECT: EXPANION OF IWTP-8 STAGE-4 DBO
OWNER: MARAFIQ
SSEM: SAUDI SERVICES FOR ELECTRO MECHANIC WORKS CO.
TITLE: Method Statement for Installation of Underground Piping
REVISION REV. DATE PREPARED BY REVIEW BY APPROVED BY Page No.

00 July 26, 2022 IA QC AL 1 of 27
Project: Expansion of IWTP-8 Stage-4 DBO
P.O. # 7200040907
METHOD STATEMENT FOR

INSTALLATION OF UNDERGROUND
PIPING & PUDDLES
Document No. 7200040907-JWWF-MCMS-02 Rev. 00
Owner/Client: MARAFIQ
PMC: ILF CONSULTING ENGINEERS
SSEM: SAUDI SERVICES FOR ELECTRO MECHANIC WORKS CO. (CJSC)
P.O. # 7200040907
OWNER: MARAFIQ

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Table of Content
SECTION DESCRIPTION PAGE
1.0 PROJECT DESCRIPTION 3
1.1 PURPOSE AND SCOPE 3
2.0 REFERENCES AND STANDARDS 4
3.0 ACRONYMS, ABBREVIATIONS & DEFINITIONS 5

4.0 RESOURCES AND MANPOWER 5
5.0 RESPONSIBILITIES OF KEY PERSONNEL 6
6.0 WORK PROCEDURE 8

WALL PENETRATION (PUDDLES FLANGE
6.6.2 23
CONNECTION)
7.0 HSE REQUIREMENTS 25
8.0 DOCUMENTS AND PLANNING 26
9.0 PLANT & EQUIPMENTS 26
10.0 QUALITY CONTROL AND ASSURANCE 27
11.0 TRAINING 27
Doc No. 7200040907-JWWF-GC-060 Rev 00 P.O. # 7200040907

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1.0 PROJECT DESCRIPTION

MARAFIQ is a Power & Water Utility Company for Jubail and Yanbu, desires to expand IWTP-8 which will be called Stage-4
with treatment capacity of 125,000m3/day. The plant will be designed to have layout for future Re-use treatment plant that
will further treat 80,000 m3/day of IWTP-8 Stage-4 effluent to meet Demineralization Feed water quality.
The Expansion project contract is based on a Design, Build and Operate (DBO) concept broken down into an Engineering,
Procurement and Construction (EPC) part and an Operation and Maintenance (O&M) part. The EPC project duration will be
for 36 months from Commencement Date, while the O&M period of the contract will be for 5 years from Initial Acceptance of
the Works from MARAFIQ.
For further details, refer Document No. MSCF-1-PC-057 Attachment D EPC Scope of Work of Contract
The SSEM will provide design and construction drawings, supervision of work, labor, construction plant and equipment,
materials, tools, Quality control and coordination to execute the works in accordance with the relevant design drawings,
Standards and specifications.
1.1 PURPOSE AND SCOPE
1.1.1 PURPOSE
This document describes the buried installation of Glass Reinforced Plastic pipes and fittings manufactured by Future Pipe
Industries (Vendor as Reference) It is to be used in conjunction with the Glass Reinforced Plastic Product Data, Method
statements, etc. and is intended to assist the installer in understanding the requirements and procedures for the successful
installation of Glass Reinforced Plastic pipes and fittings.
This manual shall be carefully read by the Contractor responsible for laying the pipe as well as the pipeline Design
Engineer. This information should be considered as a guide. The Engineers or other personnel involved in pipeline design
or laying shall establish by themselves the procedures best suited to the actual site conditions. Sound engineering
practices should always be followed.
1.1.2 SCOPE
This Method Statement is applicable to Expansion of IWTP-8 Stage-4 DBO Project. This document address the usual
circumstances that may be encountered in the field. Unique situations requiring special considerations are not addressed
and should be resolved in coordination with the manufacturer.
Instructions in this document are complete to the extent possible. However, Future Pipe Industry’s experienced
Representatives or Engineers can opt for an alternative or optimum solution for the issues not addressed in this document.
The scope can be used for all types of underground piping under this project but not limited to GRP piping only. Reference
shall taken from project IFC drawings. The Latest techniques, industry standards and sound engineering practices shall
always be followed.
Future Pipe Industries Engineers or Representatives shall be consulted for any clarifications or statements made in this
document.
Definition of words used in these instructions:
- The word “shall” indicates a requirement.
- The word “should” indicates a recommendation.

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1.1.2.1 (Vendor TBA) SCOPE OF WORK FOR FIELD SERVICES
(Vendor to be confirmed) will provide the Field Services for the Fiberglass Piping system to the Client on a full-time basis
throughout the agreed duration in the Client's purchase order.
The Field Service Representative is made available to validate the work executed by the Client in the following areas:
handling, storage, bedding, laying, jointing, backfilling, and site testing procedures necessary to achieve a satisfactory
installation of the Fiberglass system supplied by vendor, are following the applicable guidelines at the time of installation.
The Client's responsibility is to make available the documents listed in this scope package to its installation crews and
ensure that they are familiar with these documents and their contents.
The Installation Contractor should also consider any supplementary Installation Instructions published for specific
applications not covered in this document as valid documents for the work execution.
It is the responsibility of the Contractor to follow and implement the published installation instructions, manuals, and any
additional advice given verbally or in writing by the Field Service Representative.
Any failures occurring on-site related to installation, from a client's failure and/or its Contractor, a subcontractor, to follow
and implement the company's written installation instructions and any additional advice or recommendations given by the
company's field Service Representative. It is explicitly agreed by the Client that the role of vendor representative is strictly
to validate that the work executed by the Client is in line with the standard procedures of vendor, applicable at that time. By
placing an order for a Field Service Representative, the Client explicitly accepts the role and responsibility of the vendor
Field Service Representative as defined herein.
2.0 REFERENCES AND STANDARDS
All work done in the scope of contractor will be executed in accordance, but not limited, with the following documents. Where
specifications are not clear or covered by these documents the client will be informed and applicable documents will be
provided by the client in order to have clarity on requirements that should be achieved.
following references & standards are applicable to this MOS:
• ASTM D1586 Standard Method for Penetration Test and Split Barrel
Sampling of Soils
• AWWA C950 Standard Specification for Fiberglass pipes
• AWWA-M45 MANUAL FIBERGLASS PIPE DESIGN
• ASTM D2487 Classification of soil for Engineering Purpose
• ASTM D3839 Standard Practice for Underground Installation of

“Fiberglass Pipe”
• BS8010 Part 1:89 Pipe Lines on Land-General

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• BS8010 Part 2.5:89 Pipe Lines on Land-Design Construction & installation of GRP
pipelines
• BS8010 part 3:93 Pipe Lines-Sub- Sea: Design, Construction & Installation
• Contractual Requirements and Specification per IFC package and other contractual documents.
3.0 ACRONYMS, ABBREVIATIONS AND DEFINITIONS
3.1 ACRONYMS, ABBREVIATIONS
SSEM Saudi Services for Electro Mechanic Works Co. (Closed Joint Stock Company)
PMC Project Management Consultant
ISO International Organization for Standardization
OEM Original Equipment Manufacturer
EPC Engineering, Procurement and Construction
O&M Operation & Maintenance
IFC Issue for Construction
PM Project Manager
CM Construction Manager
QMS Quality Management System
QA Quality Assurance
QC Quality Control
Contractor The main Contractor of Project
Sub-contractor Construction Sub-Contractor
ITP Inspection & Test Plan
RFI Request for Inspection
NCR Non-Conformance Report
GRP Glass Reinforced Plastic
HSE Health Safety and Environment
MSDS Material Safety Data Sheets
PPE Personal Protective Equipment
PTW Permit to Work
DN / PN Design Pressure / Nominal Pressure
4.0 RESOURCES AND MANPOWER

The team members in all key positions, which require approval from the client, has been submitted to the
client for pre-approval and are being in approved stage. Positions not requiring approval from the client will
have the required qualified and experienced needed for their position in order to complete their
responsibilities successfully. The material Vendor representative shall be all time available for site work for
any advice/guidance or field query resolution along with making sure that industry standards as mentioned in
this statement are implemented in stricter quality requirements.
SSEM sub-contractors will be employed any time when there is need to adherence to vendor/client standards
or to accelerate progress but will function as part of SSEM’s team. List of SSEM sub contractors will be made
available once their qualification is approved by the client and mobilized to site.

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Organization Chart
SSEM PM – Wael Fathy

Mohammed
CONSTRUCTION MANAGER
AHMED IBRAHEEM
QA/QC MANAGER
MOHAMMED ISMAIL ELDEEB SAFETY MANAGER
NADJME
QA / QC CIVIL LEAD ENGINEER /

MECHANICAL/ PIPING SITE ENGINEERS ELECTRICAL/ INSTRUMENTATION
SUPERVISOR /
LEAD ENGINEER / MUSAAB KHALID / HUSSAM, LEAD ENGINEER /
INSPECTOR
Alaa Lotfy BENJAMIN, MAGDY, YAZAN, SITE ENGINEERS
WALEED / AZHAR MUKHTAR
CAEMAR / ZAMAN TBA
MECHANICAL SUPERVISORS CIVIL SUPERVISORS ELECTRICAL SUPERVISORS
PTW COORDINATOR
TBA
SITE EXECUTION LEADMEN / SITE EXECUTION WORKERS

TBD
5.0 RESPONSIBILITIES OF KEY PERSONNEL
All actionable responsibilities mentioned in this section for each position will be completed and available on
site from start to completion of the scope of work.
5.1 CONSTRUCTION MANAGER
The Construction manager will be responsible for the overall implementation and monitoring of all the
activities involved in the work.

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5.2 Civil Engineer
The site Civil engineer shall be overall responsible for piping excavations and trench work. He shall
also supervise dewatering subcontractor. He shall be assisted by Mechanical Piping engineer for
design requirements. Civil engineer shall also plan for shoring wherever needed. He shall have in-
depth knowledge about the practical methodology for the installation of underground piping
procedures and planning schedule on site. He must have knowledge about civil excavation work. He
will do proper planning and coordination in order to ensure that piping and fittings shall rest on sand
bedding and backfilled after testing with desired performance and efficiency as per contractual
requirements and IFC drawings.
5.3 QA/QC MANAGER

Managing the development and implementation of the QMS for planning, fabrication, inspection,
documentation, and operations activities including: Planning duties within the QA/QC staff and related
work schedules.
5.4 QA/QC Engineer

The QA/QC engineer will be responsible for the quality aspects of the works. He will assure that the
QA and QC plan will be implemented.
The required (RFIs) will be submitted to the MARAFIQ/ILF. He will proactively coordinate with the
material engineer and issue appropriate internal (Site Instructions) when he sees that performance of
earth works deviate from the approved method of statement or project specifications.
5.5 SITE CIVIL FOREMAN

The Site Civil Foreman will be in charge for the supervision and implementation of all piping
excavation work. He shall also supervise earth work equipment as guided by dedicated civil engineer.
He should have through training and knowledge about excavations and trench work. Also he shall
have complete information about piping installation and backfilling procedures.
5.6 SAFETY MANAGER

Conduct the safety induction courses to all personnel involved in the work. Monitor and supervise the
risk assessment. Ensure that necessary Permit to Work is available.
Ensure that the procedures and risk assessment are understood, complied and applied in the
worksite.
Ensure that all workers are provided with enough/complete information regarding workplace hazards
and planned control measures.
5.7 COORDINATOR

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Responsible for taking all necessary steps to prepare, authorize, and issue the Permit to Work after
assessing the work and work site and/or area hazards and the controls to address these hazards.
6.0 WORK PROCEDURE
6.1 LOWERING
Manual lowering of small diameter pipes into the trench can be executed by at least two men. It is
recommended that the weight carried by one man do not exceed 20 kg. Pipes weighing up to 120 kg
can be lowered by means of two ropes The ropes must be anchored to stakes as indicated in Figure.
1.
FIGURE- 1

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Mechanical lowering is used for larger diameter pipes, especially when combined with pipe assembly in the trench.
Two straps or slings can be used from an excavator boom if no separate lifting equipment is available as per Fig.2.
Figure- 2
Note: - Project specific handling and storage method statement shall be referred for more details of handling and storage
techniques
6.2 TRENCH SPECIFICATIONS

6.2.1 The Trench
6.2.1.1 Excavate trenches to ensure that sides will be stable under all working conditions. Slope trench walls or
provide supports in conformance with safety standards. Open only enough trench that can be safely maintained by
available equipment. Place and compact backfill in trenches as soon as practicable, preferably no later than the end of
each working day. Place excavated material away from the edge of the trench to minimize the risk of trench wall collapse.
6.2.1.2 The trench excavations should not be too far ahead of the pipe-laying team to ensure a better control of the
trench and for safety reasons. The excavated soil should be placed on one side of the trench leaving the other side clear
for equipment and pipe handling. If the trench consists of various layers of soils, these should be placed separately to
use the stone- free granular material for back-filling.
6.2.2 Trench Width

The trench width must be maintained within certain limits. A very wide trench will increase the volume of back-filling
material required and compaction labor and effort. A very narrow trench will render laying, handling, joining of pipes and
compacting side backfill difficult. The minimum trench width(W) at the bottom of the trench for a single pipe shall be:
W=1.25XOD+300mm
Note: - Project specific AWWA-M45 calculation shall be referred for each project.
The space between the pipe and the trench wall or between adjacent pipe must be 150mm wider than the used
compaction equipment.
In poor native soil conditions and depending on pipe stiffness and burial depth, a wider trench (up to 4 x ND) might be
required.
6.2.3 Parallel pipes installed in the same trench

Where two, or more, Glass Reinforced Plastic pipes are installed parallel in the same trench, the following minimum
distance ’X’ as shown in figure 3 should be maintained to allow for enough room to place and compact the backfill
material under the pipe haunches, for all the pipes in the trench.
The minimum spacing ‘X’ must be two third of the average radii of adjacent pipes for a cover depth less than 3.5m and
average of the radii of adjacent pipes for cover depth greater than 3.5m. However, in all the cases the spacing shall not
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be smaller than 300 mm. If mechanical compacting equipment is used, the minimum space between the pipes and trench
wall or adjacent pipe shall not be less than width of the widest piece of equipment plus 150mm.
FIRGURE - 3
6.2.4 Pipes Crossing
Where two Glass Reinforced, Plastic pipes are crossing each other as shown in figure 4, the minimum vertical distance
between the two pipes shall be at least the average of the radius of the two pipes, in any case this distance should not be
less than 300 mm.
Figure - 4
6.2.5 TRENCH DEPTH

6.2.5.1 Minimum cover depth
To Preclude damage to the pipe and disturbance to pipe embedment, a minimum depth of backfill above the pipe should
be maintained before allowing vehicles or heavy construction equipment to traverse the pipe trench. The minimum depth
of cover
should be established based on an evaluation of specific project conditions, such as pipe diameter and stiffness, soil
type and stiffness, and live load type and magnitude.
Project specific AWWA-M45 calculation shall be referred and installation parameters to be strictly adhered for each
Doc No. 7200040907-JWWF-GC-060 Rev 00
project. P.O. # 7200040907
If a risk of pipe flotation occurs, the minimum cover should be 1 pipe diameter. If a specific analysis is made of the
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buoyant force of an empty pipe compared to the submerged weight of soil over the pipe, this minimum cover may be
reduced.
In the presence of permanent traffic loads, a minimum cover above pipes shall always be maintained. A detailed
engineering should be carried out and installation parameters as per AWWA-M45 calculation shall be strictly followed.
In case of high ground water table, a minimum cover depth equal to 0.8 times the pipe diameter of granular soil (minimum
dry density of 1300 Kg/m3) must be provided to prevent Glass Reinforced Plastic pipes from floating. Always ensure that
this minimum cover is available before turning off dewatering systems.
6.2.5.2 Maximum cover depth

The maximum cover height depends on the type of installation, backfill material and its compaction, pipe stiffness class
as well as the native soil conditions.
6.3. SPECIAL UNDERGROUND REQUIREMENTS

6.3.1 Road Crossing
Road crossings require special attention and requirements. Precautions shall be taken to protect the pipes, which cross
underneath roads against the possible consequences of traffic loads. The influence of the wheel load of traffic passing a
buried pipe reduces with increased burial depth. Minimum cover depth can be reduced with special installation such as:
I) Sleeve pipe.
Ii) Concrete Protection Slabs.
Iii) Concrete encasement of the pipe.
The below details are considered as a guideline, prior to apply these methods, site team to align with Engineering team to
collect the relevant details of the protection slabs.
I) Sleeve Pipe.
The Glass Reinforced Plastic pipe is nested inside a sleeve pipe. To avoid direct contact between both pipes, spacers
are used to center the GRP pipe inside the sleeve pipe (Figure- 5). The annular space between the two pipes is grouted.
The sleeve pipe should be longer than the width of the road.
Ii) Concrete Protection Slabs.

Two types of concrete protection slabs exist:
a)Doc No. 7200040907-JWWF-GC-060
Concrete Relief Plate. Rev 00 P.O. # 7200040907
b) Protection slab at grade level
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a) Concrete Relief Plate:
This protection slab is specially designed and dimensioned to minimize the transfer of wheel load on the pipe
and divert the load away from the pipe (Figure-6). The plate has a rebate which a
Figure-6 Concrete Relief Plate 1
b) Concrete Protection Slab at Grade Level

This concrete slab (Figure-7) dissipates the effect of traffic loading and minimize the transfer of wheel load on the pipe by
increasing the contact surface between the vehicle wheel and the soil. The concrete slab must be with appropriate length
to ensure that the slab is rested on undisturbed walls of the trench.
The Height (H) between the pipe and concrete protection slab will be based on the actual burial depth at site.

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Figure 7: Concrete Protection Slab
Iii) Concrete encasement of the pipe.

Encasing the pipes in concrete is an alternative to protect the pipe from excessive traffic load. Precautions to be taken
while encasing the concrete are explained below.
Pouring concrete around the pipe results in uplifting forces that can damage the pipe and /or joint. To avoid such
movement, the pipe should be anchored downward by straps hooked to a rigid base as shown in figure 8.
The straps should be of flat material of minimum 25 mm width and strong enough to withstand flotation uplift
forces. The distance between straps should not exceed 4 meters, with a minimum of two strap per section length. The
straps should be tightened to prevent pipe uplift, but should not be over-tightened to avoid additional pipe deflection.
Therefore, the straps should be loose when pouring of concrete reached the pipe springing level. And after the poured
concrete get hardened. Then pouring shall be directly compacted till reaching the pipe crown
Figure 8 - Pipe anchored by straps
The pipe should be supported in such a way that the concrete can easily flow completely around and fully underneath the
pipe. Also, the supports should result in an acceptable pipe shape (less than 3% deflection and no bulges or flat areas).
The concrete must be placed in stages allowing sufficient time between layers for the cement to set and no longer exert
buoyant forces
6.4 BACKFILL AND INSTALLATION SELECTION
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The installation type and choice of Pipe Embedment Zone material is normally specified by the design engineer, based
on the specified pipe stiffness class, maximum burial depths, depth of water table, wheel load, and native soil conditions.
Note: - Project specific AWWA-M45 calculation shall be referred for each project.
6.4.1 Foundation, Bedding and Backfill materials.

Most coarse-grained soils are generally acceptable as backfill material for the foundation and pipe embedment zone.
The maximum particle size is as follows;
Table 1 - Maximum Particle Size
Pipe Diameter Maximum particle Size
DN < 450 mm 13 mm
450 mm < DN < 600 mm 19 mm
600 mm < DN < 900 mm 25 mm
900 mm < DN < 1200 mm 32 mm
DN > 1200 mm 38 mm
If the native soil meets the specifications in tables 1, the same soil may be used in the Pipe Embedment Zone.
6.4.2 Migration
When backfill materials such as gravels and crushed rocks are placed in a trench adjacent to a finer native material, the
finer material may migrate into the coarser material under the flow pressure force of the ground water table. Migration
can also occur when selected sand is used as backfill in a trench where the native soil is coarser.
Significant hydraulic gradients may arise in the pipeline trench during construction, when water levels are controlled by
various pumping or well-pointing methods.
Gradients may also arise after construction, when permeable underdrain or when the open graded embedment materials
act as a “French” drain under high ground water levels. Migration can result in significant loss of pipe support and
increasing pipe deflections that may eventually exceed the design limits of the Glass Reinforced Plastic pipe.
The gradation and relative size of the embedment and adjacent native soils must be compatible to minimize migration. In
general, where significant ground water table is above the foundation or bedding level and when the native soil is a finer
than the backfill, avoid using open graded materials such as crushed rocks and gravel, unless a geotextile filter fabric is
used to line the trench.
The following gradation criteria may be used to restrict the migration of finer material into a coarser material under a
hydraulic gradient.
• D15 I d 85 < 5 where Dis is the sieve opening size passing 15 percent by weight of the coarser material and ds is
the sieve opening size passing 85 percent by weight of the finer material.
• D so / d50 < 25 where D so is the sieve opening size passing 50 percent by weight of the coarser material and is
the sieve opening size passing 50 percent by weight of the finer material. (This criterion doesn’t apply if the
coarser material is well graded)
6.4.2.1 Geo-textile Filter Fabric

The Geo-textile Filter Fabric shall consist of thermal bonded/needle punched synthetic polymer fibers. Composed of at
least 85 percent by mass polyolefins, polyesters, polypropylene, polyethylene or polyamides. They shall be formed into a
network such that the filaments or yarns retain dimensional stability relative to each other, including selvages.
The fabric shall be stabilized against ultra violet light, inert to commonly encountered chemicals in the in-situ soil and
saline water.
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Minimum property requirements should be as per the international standards and the end user requirements. Figure-9
represent the usage of geotextile to prevent the intermixing of dissimilar soil layers
Figure 9- Geo-textile placed in between dissimilar soil layers
Geotextile filter fabric shall be lined at the bottom, sides and top of the pipe embedment zone. This can be same
as a gift wrapping method along with the backfill material.
Sequence of Geo-textile Application.

1. Placing the Geo-textile to line the trench bottom and sides. See Figure-10
2. Bedding and Pipe laying on the Geo-textile. See Figure-11
3. Back-filling with appropriate backfill materials. See Figure-12
4. Covering the embedment zone with Geo-textile. See Figure-13
Figure 10: Placing the geotextile to line the trench bottom and sides.
Figure 11: Bedding Rev

Doc No. 7200040907-JWWF-GC-060 and 00
Pipe laying on the geotextile P.O. # 7200040907
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Figure 12: Back-filling with appropriate backfill materials
Figure 13: Covering the embedment zone with Geo-textile
```

PROJECT: EXPANSION OF IWTP-8 STAGE-4 DBO
OWNER: MARAFIQ
Revision REVISION REV. DATE PREPARED BY REVIEW BY Page No.

Rev. Date 00 July 26, 2022 IA QC 17 of 27
6.4.3 Buoyancy High Water Table

Water table is an important topic when it comes to underground installation. When the water table rises above the
foundation of the trench dewatering measures shall be employed to drain the water such that installation can be carried
out in dry trenches. Buoyancy check shall be carried out by manufacturer technical team to understand the minimum
cover depth required to counter act the uplift forces. Suitable engineering measures such as anchor straps, usage of
Geo-grid, counterweight, etc. may be proposed after analyzing the actual scenario on cases by case basis.
Note: -
Dewatering equipment shall be turned off only after reaching sufficient counter weight as computed by the technical
team for empty pipe scenario.
6.4.4 Determination of native soil properties

To choose the appropriate installation type and to identify the allowed burial depth limits, it is necessary to determine
native soil properties. Proper soil investigation along the pipeline route is an engineering practice that should be
executed by the Contractor in case no soil data is provided by the end user. When no soil data is available, borehole
samples should be taken along the pipeline route at intervals of not more than 500 meters. If the native soil properties
and appearance are not consistent over this distance, shorter intervals for sampling should be adopted. Soil samples
must be taken from a depth that provides the necessary information at the pipe embedment zone level of the pipeline.
Important soil properties:
- Physical characteristics, appearance, and gradation
- Water table location
- Blow counts (N) per ASTM DI586 (Standard Penetration Test
6.4.5 Classification of native soils

Native soils can be classified into five main groups and two sub groups; cohesive and granular.
Table 2 - Native Soil Groups
1 2 3 4 5 6 7
Blow counts,
N
>50 30-50 15-30 8 - 15 4-8 2-4 1-2
(ASTMD
1586)
Cohesive Soils Very Hard Hard Very Stiff Stiff Medium Soft Vety Soft
Very Slightly Very

Granular Soils Dense Compact Loose
Dense Compact Loose
6.4.6 Alternative Installations

If the burial depth requirement for the selected pipe stiffness, installation type and native soil group exceeds the limits
given in project specific AWWA M45 calculations, three alternative installation methods may be considered:
• Wider Trench
• Permanent Sheeting
• Cement Stabilized Backfill

OWNER: MARAFIQ

6.4.6.1 Wider Trench

Increasing the trench width allows a deeper installation.
6.4.6.2 Permanent Sheeting
Permanent sheeting can be used to distribute the pipe’s lateral loads appropriately. The sheeting should be at least 300
mm higher than the pipe crown level and driven below the foundation level. The sheeting system is to be designed by a
specialist and the material to be of quality to last the lifetime of the pipe.
6.4..6.3 Cement Stabilized Sand Backfill
Cement stabilized sand is a mixture of one sack of cement (50 kg) and one ton of clean sand. This backfill material
provides excellent support for Glass Reinforced Plastic pipe where native soil conditions are poor. The mixture should
be placed in the foundation, bedding, haunches and Pipe Embedment Zone in layers of 15-20 cm. each layer should be
wetted with clean water and compacted with plate vibrators before the cement sets
6.4.7 Pipe bedding and foundation

To ensure a firm support for Glass Reinforced Plastic pipe, a proper bedding must be provided under the pipe. During
trench excavation, a pipe bedding thickness of at least 150 mm must be provided. In case of very poor native soils (silt,
clay or mud) an additional 150 mm thick foundation layer must be provided below the bedding. Selected backfill material
should be placed at the foundation and bedding layers and thoroughly compacted by plate vibrators or by hand
tamping. Wetting of sand bedding/foundation material prior to compaction will improve and facilitate the achievement of
the degree of compaction required.
Reference shall be made to the soil investigation report to determine the foundation thickness for the specific site
conditions.
Pipe laying should always take place in dry trenches. It is not acceptable to lay pipes in flooded trenches. The
installation Contractor should provide the necessary dewatering equipment to enable installation to proceed in a dry
trench. Dewatering equipment should be removed, and pumps turned off only after completion of backfilling the Pipe
Embedment Zone, and enough backfill has been provided to prevent pipes from
6. floating, if the normal ground water level is above the pipe invert.
Prior to lowering of the pipe into the trench small holes should be dug under each joint location (Figure-14) so the pipe
does not rest of the joints. The bedding material should provide firm and contentious support over the entire length of
the pipe excluding the joint areas.
Figure-14 - Proper bedding and support for joints

OWNER: MARAFIQ

Figure-15- Improper bedding and lack of supports for joints
Pipes shall be lowered into position after checking the proper levels and alignment of the pipeline. Pipes shall be laid
perfectly horizontal and avoid resting the pipe ends on sand piles to avoid any steps between the pipes that will result
the coupler insertion difficult.
6.4.8 Pipe Embedment Zone
The selected backfill material should be evenly placed and properly compacted on both sides of the pipes. Appropriate
hand or mechanical tamping shall be carried out by the Contractor to achieve the specified degree of compaction
required by the selected installation type. During the first one or two lifts (lift height shall not exceed 250mm), special
care should be taken to place and compact the backfill material under the pipe haunches (Figure-16). The best way to
achieve this compaction is to do it manually with the help of a wooden board. This is one of the most important
installation steps and should be executed with care. Failure to place and to compact the backfill material under the pipe
haunches may cause deformation, localized loads and over deflection of the pipes (Figure-17)
Figure-16-Pipes laid with haunches properly compacted.

OWNER: MARAFIQ

Notes:
1. Trench wall inclined shall be as per the soil characteristics and angle of repose.
2. Foundation thickness must be in line with the Geo-technical recommendations.
3. The first two lifts ate the pipe zone embedment shall not exceed 250mm.
Pipes joined in the trenches should not be left for long periods without back-filling as some joints may rupture due to
daily expansion and contraction of the pipes due to ambient temperature fluctuation. However, if the pipes are
sufficiently restrained to prevent movement, the joints may be left exposed for an easy visual inspection during the field
hydro-test. These joints must be back-filled immediately after the test to avoid damages.
The Contractor should note that the compaction of clean and mixed sands is best achieved when the material is at its
optimum moisture content. While the wetting of sand is recommended prior to compaction, trench flooding should be
avoided to prevent pipes from floating.
Following the first two layers where the backfill has been sufficiently placed, compaction should proceed from the sides
of the trench towards the pipe. The Pipe Embedment Zone backfill should proceed in 150 to 300 mm lifts depending on
backfill type (see section 6.1). For Gravel backfill 300mm lifts are permitted. The Pipe Embedment Zone backfilling, and
compaction should continue until the backfill reaches at least 15 cm above the pipe crown. For pipes, larger than 1000
mm in diameter, back-filling the Pipe Embedment Zone should continue to 300 mm above the pipe crown.
After completion of backfilling in the Pipe Embedment Zone, native material excavated from the trench may be used to
complete backfilling to final grade. No compaction is required in these final backfilling layers except where specified by
the Engineer, or in the case of traffic or other high external loads over the pipe where settlement of the native backfill is
to be avoided.
Caution:
Sand layers of more than 300 mm cannot be compacted properly and may result in loss or reduced support for the
pipes. The best compaction results are achieved with wet sand near its optimum moisture content. Flooding of the
trench must be avoided as pipe floatation may occur. A minimum of 1 pipe diameter of granular backfill is normally
required to prevent Glass Reinforced Plastic pipes from floating.
For backfill material such as Gravel (Class I) and Sand (Class II) a 200kg plate vibrator is required to compact the backfill
in 15cm layers, and a 500kg plate vibrator is required to compact the backfill in 30cm layers. For Class-Ill and Class-IV
backfill materials a 500kg plate vibrator is required to compact the backfill for both lift cases. Before using plate vibrator

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directly above the pipe crown,

insure that backfill reaches 25cm above pipe crown for 200kg vibrators and that backfill reaches 50cm above pipe
crown for 500kg plate vibrators.
6.4.9 Temporary sheet piles and Shoring
Special attention and care from the Contractor’s side is required when the Glass Reinforced Plastic pipes are
backfilled in sheeted trenches. If sheeting or trench shoring is withdrawn after compaction, hollow spaces will be left
and soil pipe support will be lost or reduced.
Caution:
Sheet piles must be withdrawn in stages as backfilling progresses in such a way that all hollow spaces left behind the
sheeting are filled with compacted backfill material.
6.5 SYSTEM ASSEMBLY

Glass Reinforced Plastic pipes are generally joined using Double Bell Couplings in buried installation. Other jointing
system such as flanges (inside chambers), adhesive bonded joints, mechanical couplings, Rubber seal lock joints,
REKA Seal Lock Joints and lamination joints may also be used for joining the Glass Reinforced Plastic pipes. PVC
piping also joined with adhesive using coupler or directly pipe to pipe or with fittings insertion.
Refer to the relevant method statements to perform the jointing activity. It is the installation contractor's responsibility to
make the necessary method statements available to the installation team members.
6.6 SPECIAL REQUIREMENTS

6.6.1 Standard short pipe lengths
Standard short Glass Reinforced Plastic pipe lengths are required in various situations, such as:
Outside rigid structures (i.e. water reservoirs, pumping station, thrust blocks, valve chambers, manholes etc.)
To connect the pipes to a line fitting such as bends or tees inside thrust blocks.
Standard short lengths of pipes shall be planned by the Contractor. Standard short pipe length can be 1.5XND with a
minimum of 500mm and a maximum of 2000mm. The length (L) may follow in between a range as per the below on a
case-to-case basis.
L=Smaller of 2m or 2XND
L= Smaller of 0.5m or 1XND

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Figure-18-Standard Installation
Figure-19 -Alternate Installation
Cautions:
The expected settlement for massive concrete structure shall be calculated by the geotechnical engineer to determine
the number of short pipes & couplers required to withstand the settlement without excessive loads onto the pipes.
Backfilling around the concrete structures shall be thoroughly compacted with the same selected backfilling material. It
is the engineering team to decide the most suitable option to be followed based on their analysis.
6.6.2 Wall Penetration- ( Puddle Flange Connections)

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Figure-20
Figure - 21

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Figure - 22
6.6.3 Thrust blocks and anchoring

Thrust blocks shall be designed as per requirement during advance engineering stage. As a guide thrust blocks must be
used in pipeline systems wherever thrust loads are expected, such as at:
• Changes of direction (bends, Tees, Wyes)
• Cross section changes (reducers)
• Valves and hydrants
• Dead ends.
The thrust blocks can be dimensioned and designed as per the expected thrust load as well as native soil properties.
Thrust block spaces must be foreseen in the design and trench excavations. At vertical bends, the line or the bend must
be anchored by thrust blocks or other means to resist outward thrusts. Thrust blocks must be cast against undisturbed
trench walls (native soil) and must completely encase the Glass Reinforced Plastic fitting (except at the joint area). The
maximum allowable displacement of fittings is 0.5% of the diameter, or 6 mm; whichever is less. The outlet part of the
encased Glass Reinforced Plastic fitting in the concrete block shall be rubber wrapped as shown above in figure 22. See
appendix II for additional information about thrust blocks.
Note: Gravity lines up to 1 bar design pressure do not require thrust blocks.
Caution:
Always provide a standard short pipe outside thrust blocks (see section 6.1) to protect the pipeline from differential
settlement.
Nozzle connections should not necessarily be concrete encased. Nozzles are tee branches meeting all the following
criteria:
1. Nozzle diameter < 300 mm
2. Header diameter > 3 times nozzle diameter
3. If the nozzle is not concentric and /or not perpendicular to the header pipe axis, the nozzle diameter shall have
considered to be the longest cord distance on the header pipe wall at the nozzle/pipe intersection.
Caution:
Exposed length of fitting shall be considered while designing the thrust volume (minimum distance as shown into

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figure 18 - options 1) shall be considered
6.6.4 Hybrid system
Hybrid system is a technique in which a combination of restrained and non-restrained piping system is
being employed to eliminate the use of thrust blocks. It is an ideal system where dimension constrain exists
due to limited space availability such as in plant piping. It is recommended to carry out a detailed
engineering to determine the minimum required restrained lengths to be used at the locations of direction
changes, Tees, Reducers, End caps, etc.
7.0 HSE REQUIREMENTS

Entrapment, hits and run over by vehicles
I. Collective systems and organizational measures
• Avoid workers staying inside machinery work zones
• Have a clearly marked loading/unloading area
• Coordinate and supervise vehicles displacements, especially reverse ones
II. PPE: Reflective safety vest, safety shoes and safety helmet
Vehicle overturning
• Avoid the circulation and staying of vehicles at a distance smaller than 4m from excavation borders
• Coordinate and supervise vehicles displacements, especially reverse ones.
Falling from height
• Close excavation with fences
• Preparation of wide and moderate slope ramps as trenches access.
• Do not climb trenches walls
Entrapments and burials by detachments

• Daily inspection of trenches walls looking for cracks or unstable materials, especially during and after rainy
conditions
• Cleaning and removal of material in excavation borders in case of caves appearance
• Avoid the circulation and staying of vehicles at a smaller distance than 4m from excavation borders
• Avoid any material storage at a smaller distance than 4m from excavation borders
• Not allow entrance of not accompanied workers in trenches
• For stable soil, it is allowed a 90° slope between ground and walls. For rest of the types sloped trench walls
should be arranged

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Fire, explosions because of existing conductions (gas, etc.)

• Obtain all available information about existing underground conditions
• Stop all works in case of appearance of sand and/or colored straps during excavations
• In case of pipe breakage turn off all the machinery, stop all the works and avoid any source of flames or sparks.
Leave the area and inform to supervisors.
Cuts, hits, abrasions

• Cover rebar’s ends with plastic protections
Loads falling

• Delimited loading/unloading area
• Avoid under load zone
• Respect crane safe loading chart
• Inspect slings to detect damages
• Use two lifting points being symmetrical to the pipe's center of gravity.
II PPE: Safety helmet
8.0 DOCUMENTS AND PLANNING
Work will be performed in accordance with the APPROVED documents; IFC Drawing for Building, Tanks,
Foundation and other structural elements, planning schedule will be updated for delivery and shifting of
material. All lead mechanical engineer site mechanical engineer and material engineer shall have a 3-
weeks look ahead schedule of GRP stock inventory.
9.0 PLANT & EQUIPMENTS
SSEM will provide the following equipment throughout the project; quantities will be determined by actual
site/Store demand. Equipment will be inspected prior utilizing.
10.0 QUALITY CONTROL AND ASSURANCE
All records relevant to the above procedure will be retained by the Quality Control department in the site
office, for the duration of the project, before being handed over to the Contractor in accordance with the
requirements of the contract documents. Copies of all records will be made and transferred to the
Contractor Office where they will be retained for the guarantee period of the contract.

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 Approved MR I/ RFI
 IFC
 Approved Material Receiving RFI
11.0 TRAINING
Training will be providing as per training and project schedule.
 HSE Induction and General Safety Awareness Training

 Heat Stress Awareness Training
 PTW (Permit to Work) Procedure Training
 Lifting and rigging activities at Store / Site.
 Quality Induction Training
 First Aid Training
 Lamination / jointing work Training

Method Statement For Underground Piping & Puddles Installation

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Method Statement For Underground Piping & Puddles Installation

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PROJECT: EXPANION OF IWTP-8 STAGE-4 DBO

SSEM: SAUDI SERVICES FOR ELECTRO MECHANIC WORKS CO.

TITLE: Method Statement for Installation of Underground Piping

REVISION REV. DATE PREPARED BY REVIEW BY APPROVED BY Page No.

Project: Expansion of IWTP-8 Stage-4 DBO