Quality Management System Job Code:

Project Quality Plan, Issue: Rev: 00

JMC PROJECTS (INDIA) LIMITED
Document No. Date :24.11.2020
JMC-MWSP-W-DI-MST-R-00
Client: Ministry of National Planning, Housing and Infrastructure, Govt. of the Page 1 of 19
Republic of Maldives.

Method Statement for Di Pipe Laying & Jointing Works

Rev No: 00
Date:
Prepared by Reviewed by Approved by
Kumar Abhishek

REVISION HISTORY

Date of
Rev. No. Description of Change Author Reviewer
Revision

Page |1
Project Name: MWSP, Maldives.
DOC No: JMC-MWSP-W-DI-MST-R 00
 Quality Management System Job Code:
Project Quality Plan, Issue: Rev: 00
JMC PROJECTS (INDIA) LIMITED
Document No. Date :24.11.2020
JMC-MWSP-W-DI-MST-R-00
Client: Ministry of National Planning, Housing and Infrastructure, Govt. of the Page 2 of 19
Republic of Maldives.

Content

1.0 Purpose and Objective

2.0 Scope

3.0 References

4.0 Responsibilities

5.0 Resources

6.0 Procedure

7.0 Quality Assurance

8.0 Health, Safety and Risk assessment

9.0 Environmental Conservation

10.0 Attachments

Page |2
Project Name: MWSP, Maldives.
DOC No: JMC-MWSP-W-DI-MST-R 00
 Quality Management System Job Code:
Project Quality Plan, Issue: Rev: 00
JMC PROJECTS (INDIA) LIMITED
Document No. Date :24.11.2020
JMC-MWSP-W-DI-MST-R-00
Client: Ministry of National Planning, Housing and Infrastructure, Govt. of the Page 3 of 19
Republic of Maldives.

1.0 Purpose and Objective

The objective of this procedure is to establish a uniform, safe and systematic
working procedure, of DI Pipe Laying and Jointing work activity. The process defines
the actions for successful execution of work at site.
2.0 Scope
This procedure covers the detail work methodology and guidelines for DI pipe laying,
jointing, testing and commissioning activity in all type of strata such as soil, soft
murrum as well as hard rocks. General requirements for stacking, excavation,
laying, jointing, testing & back filling reinforcement at site as per approved drawings
and technical specifications.
3.0 References

 General Contract Requirement

 Contract Specification
 Approved Drawings
 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 12288:1987 - Code of Practice for Use and Laying of Ductile Iron Pipes
 ISO 2531:2009 Ductile iron pipes, fittings, accessories and their joints for water
applications
 IS 5382:1985 - Rubber Sealing Rings for Gas Mains, Water Mains and Sewers.
4.0 Organization and Responsibilities:
Construction Manager: Shall be responsible for control of operations and
ensure that job is commenced as per approved method statements,
specifications and drawings available at site.
Site Engineer: Shall be responsible to ensure site construction activities as per
approved method statements, specifications and drawings available at site.
Shall be responsible to coordinate with the surveyor to ensure setting out and
reference points complying with the IFC (Issued for construction) drawings.
P&M Engineer: Shall be responsible for concrete production and assistance in
pump operation and other P&M movements/activities like providing necessary
vibrators, repairs on time & material shifting and tower crane operation,
providing sufficient cutting and bending machines, providing sufficient electricity
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Project Name: MWSP, Maldives.
DOC No: JMC-MWSP-W-DI-MST-R 00
 Quality Management System Job Code:
Project Quality Plan, Issue: Rev: 00
JMC PROJECTS (INDIA) LIMITED
Document No. Date :24.11.2020
JMC-MWSP-W-DI-MST-R-00
Client: Ministry of National Planning, Housing and Infrastructure, Govt. of the Page 4 of 19
Republic of Maldives.

Land Surveyor: Shall be responsible to coordinate with construction manager

and site engineer for setting out line & levels with respect to approved
coordinates as per GFC (good for construction) drawings.
QA/QC Engineer: Shall be responsible for site QA/ QC activities, traceability,
non-conformance management and compilation of records. Ensure that all
QCI’S and Lab Technicians are properly informed as to the daily work program
and delegating actions to QCI; review of all Documentation and Reports and
Coordinating with other QC disciplines, as necessary.
HSE Engineer: Shall advise the Site Engineers, foremen, Charge hands &
workers on HSE matters related to Vehicle movement, height working and do
periodic Inspections and keep record for reference, including the daily toolbox
talk during the concreting operations.
5.0 Resources
Materials: DI Pipe & Fittings, Gasket
Manpower: Site Engineer, Site Supervisor, HSE Engineer, Quality Engineer
Equipment: The following equipment’s shall be used in order to execute the DI
Pipe laying work.
 New Generation Hydra Crane with hook latch.
 Belt type lifting sling with sufficient capacity
 Measuring steel tape, Submersible pump set
 Truck or Trailer, Mini excavator.
 Calibrated survey instrument, pressure-testing equipment.
6.0 Procedure:
6.1 Routing:
The choice of pipeline routing shall be governed by economic considerations and
other factors such as overhead and underground cables, existing pipelines and
traffic flow.
6.2 Field Survey:
Field survey for strip width representing about 500 m along the proposed alignments
shall be carried out. Any vertical section or profile along the pipeline route shall be
shown in the drawing. Special crossings, which require permission from authority,
shall be detailed on separate drawings and cross reference to the appropriate strip
plan. In urban areas, trail trenches at suitable intervals will be necessary to locate
the utilities this may affect the laying of pipes.

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Project Name: MWSP, Maldives.
DOC No: JMC-MWSP-W-DI-MST-R 00
 Quality Management System Job Code:
Project Quality Plan, Issue: Rev: 00
JMC PROJECTS (INDIA) LIMITED
Document No. Date :24.11.2020
JMC-MWSP-W-DI-MST-R-00
Client: Ministry of National Planning, Housing and Infrastructure, Govt. of the Page 5 of 19
Republic of Maldives.

Pipe laying line shall be marked with respect to datum reference line given by the
authority/customer. Marking shall be re-checked by the respective site Engineer
along with surveyor.

6.3 Site Preparation:

The area to be excavated / filled shall be cleared of fences, trees, plants, logs,
stumps, bush, vegetation, rubbish, slush, etc. and other objectionable matter. If any
roots or stumps of trees are encountered during excavation, they shall also be
removed. The material so removed shall be disposed of as approved by the
Engineer in Charge. Where earth fill is intended, the area shall be stripped of all
loose/ soft patches, top soil containing objectionable matter/ materials before fill
commences.
6.4 Unloading and Stacking of DI – Pipes:
 Entry permission shall be obtained from the site authorities prior to entering the
Lorry inside the premises where to be unloaded.
 Location of unloading area shall be finalized with the site authorities before
unloading the pipes.
 DI pipes from the Lorry / Trailer will be unloaded by using New generation Crane
/Tripod with enough man power.
 DI pipes shall be lifted by using by Cotton belts or nylon ropes, not by Wire rope
or chain slings to avoid damages on pipe.
 The place where the materials to be unloaded will be leveled for proper
placement.
 The unloaded pipes will be segregated and placed over wooden sleeper in such
way that which will not fall down from the arrangement (fig. 1, 2 & 3).
 After proper arrangement of pipes, pipe storage area, shall be properly
barricaded.
 During stacking and removal operations, safe access to the top of the stack is
essential.
 The bottom layer of pipes should be securely anchored.
 The Bottom Layer of pipe ends should be properly covered by using suitable
materials.

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Project Name: MWSP, Maldives.
DOC No: JMC-MWSP-W-DI-MST-R 00
 Quality Management System Job Code:
Project Quality Plan, Issue: Rev: 00
JMC PROJECTS (INDIA) LIMITED
Document No. Date :24.11.2020
JMC-MWSP-W-DI-MST-R-00
Client: Ministry of National Planning, Housing and Infrastructure, Govt. of the Page 6 of 19
Republic of Maldives.

STACKING: Three types of stacking are recommended as mentioned:

 Square Stacking - Suitable for pipes up to and including DN 400 ( fig: 1)
 Parallel stacking – Suitable for pipes of all sizes (fig: 2)
 Pyramid stacking – Suitable for pipes of all size (fig: 3)

fig -1 fig – 2 fig – 3

6.5 Storage of DI fittings
 Fittings must to be stored on timber and planks. However, for short durations, if
the fittings have to be stored on the ground, it must not be marshy or unstable
and must not contain any corrosive material. Flat surfaces are preferred (fig-4)
 It is always desirable to store the fittings under a covered shed to protect the
coating from the effects of weathering and prolonged exposure to the sun.

fig- 4
6.6 Storage of Rubber Gaskets
 Rubber gaskets are usually supplied in bags and should be stored in them itself
in a cool dark place.
 Rubber Gaskets should be stored away from direct sources of heat and direct
sunlight.
 Material should be issued from the stores in strict rotation of first come first out
basis.

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Project Name: MWSP, Maldives.
DOC No: JMC-MWSP-W-DI-MST-R 00
 Quality Management System Job Code:
Project Quality Plan, Issue: Rev: 00
JMC PROJECTS (INDIA) LIMITED
Document No. Date :24.11.2020
JMC-MWSP-W-DI-MST-R-00
Client: Ministry of National Planning, Housing and Infrastructure, Govt. of the Page 7 of 19
Republic of Maldives.

6.7 Land marking and excavation of trench:

Open Excavation
 Ensure necessary excavation permit /clearance is obtained from authorized
representative.
 In case of rock excavation by blasting, obtain necessary permission from the
concerned authorities.
 Mark centerline and excavation dimensions as per the requirements
(See Table No. 01).
 Special consideration should be given to the depth of trench. Minimum cover of
1000mm earth cover over crown of the pipe for laying of the pipes and fittings,
including proper stacking of excavated soil/material, backfilling and disposal of
surplus material
Table No. 01
Depth of Bottom of the pipe
Diameter (d) Width of trench bottom
Sr. No. below at ground level
of Pipe in mm d+400 mm)
(d+1000mm)
1 100 1100 500
2 150 1150 550
3 200 1200 600
4 250 1250 650
5 300 1300 700
6 350 1350 750
7 450 1450 850
8 500 1500 900
9 600 1600 1000
10 700 1700 1100

 Make shoring and shuttering of timber planks or steel frame for excavation in
sandy soil or water bearing strata.
 If the excavated soil is found sandy the same shall be used for backfilling
otherwise any other approved soil shall be used for backfilling. So dump the
excavated material away from the excavated pit, at least half the depth of
excavation.
 Keep excavation pits free from water, use-dewatering pumps if required.

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Project Name: MWSP, Maldives.
DOC No: JMC-MWSP-W-DI-MST-R 00
 Quality Management System Job Code:
Project Quality Plan, Issue: Rev: 00
JMC PROJECTS (INDIA) LIMITED
Document No. Date :24.11.2020
JMC-MWSP-W-DI-MST-R-00
Client: Ministry of National Planning, Housing and Infrastructure, Govt. of the Page 8 of 19
Republic of Maldives.

6.8 Laying of DI pipes:

 Laying Underground pipe line:
Each pipe shall be thoroughly checked for any damages before laying and get the
clearance from the authority. Pipes shall be lowered into the trench as per drawing
by using suitable tackles like new generation crane or Tripod for the weight of pipes.
In case of space constraint/unavoidable condition, if it is not possible to lower the
pipe directly to its final position (as in case of very narrow roads) then the pipes shall
be lowered at one end inside the trench and rolled carefully to its final position by
using damage proof arrangements like wooden planks with steel pipe rollers, hook
chuck etc.
Where approaches are not available to transport the pipe along the alignment, we
propose to convey the pipe manually by adopting suitable method to the location
and lower the pipe using tripod.
For smaller sizes, up to 250 mm nominal bore, the pipe may be lowered by the use
of ropes but for heavier pipes new generation crane shall be used.
All construction debris shall be cleared from the inside of the pipe either before a
joint is made. This is done by passing a pull-through in the pipe, or by hand,
depending on the size of the pipe.
When laying is not in progress, a temporary end closure shall be securely fitted to
the open end of the pipeline.
The trench shall be kept free of water till the pipe joint has to complete 100 %.
Walking on completed line shall not be permitted until trenches are back filled
 Laying Above Ground:
The ground shall be dressed to match the curvature of the pipe shell for an arch
length subtending an angle of 120” at the center of the pipes. Alternatively, the
pipeline shall be laid either on saddle, roller or rocker supports as per drawing. The
pipes may be allowed to rest on ground if the soil is non-aggressive.
6.9 Supporting Pipes above Ground:
 With Spigot and Socket Pipes
The above ground installations of spigot and socket pipes shall be provided with one
support per pipe, the supports being positioned behind the socket of each pipe as
per approved drawing.
 With Flanged Pipes
Maximum unsupported span is 8 m. The supports shall be located at the Centre of
every second pipe as per approved drawing.
Page |8
Project Name: MWSP, Maldives.
DOC No: JMC-MWSP-W-DI-MST-R 00
 Quality Management System Job Code:
Project Quality Plan, Issue: Rev: 00
JMC PROJECTS (INDIA) LIMITED
Document No. Date :24.11.2020
JMC-MWSP-W-DI-MST-R-00
Client: Ministry of National Planning, Housing and Infrastructure, Govt. of the Page 9 of 19
Republic of Maldives.

6.10 Cutting of Pipes

The cutting of pipe for inserting valves, fittings, etc., shall be done in a neat and
workman like manner without damage to the pipe or lining so as to leave a smooth
end at right angles to the axis of the pipe. Ductile iron cutting methods are given
below:
 By Hacksaw
 By Manually Operated Wheel Cutter
 By Pipe Cutting Machine
 End Preparation of Cut Pipes for Jointing
6.11 Pipeline Markers
Distinctive markers shall be erected at all roads, railways, and river and canal
crossings, to identify the pipeline and to indicate its position.
6.12 Pipeline Anchorage
It is proposed to provide anchorage in the form of “thrust block” at each deflection in
horizontal as well as in vertical alignment of the pipeline as per requirement of
designs, which shall resist the unbalanced pressure at bends.
Gravity type of thrust blocks shall be provided at horizontal and vertical deflection in
pipeline and shall be designed according to the test pressure and the soil conditions
at the site of the thrust block. The thrust shall be according to the field test pressure
of the pipe, acting on the outer diameter including the compressed rubber gasket.
Before designing the thrust block the Contractor, in coordination with the Engineer-
in-Charge shall assess the stability of the soil considering erosion due to Wind and
water.
The thrust blocks shall be of concrete M20 or grade as specified in IS 456, cast on
site with surface reinforcement as per approved drawing. There is need to provide
any reinforcement in thrust blocks to be provided on pipelines of dia. 100 mm and
above. The calculations for the dimensioning and the shape of the thrust blocks
have to be prior approved.
Pipes on slopes need to be anchored when there the backfill around the pipe is likely
to slide away or washed out due to run off in case of rains and thereby carrying the
pipe with it. Generally, for slopes up to 30º and in very good drained soil, carefully
tamped in layers of 100 mm under and over the pipe, right up to the top of the trench
will not require anchoring. For steeper slopes, pipe shall be held by straps fastened
to vertical support anchored in concrete as per the drawings.

Page |9
Project Name: MWSP, Maldives.
DOC No: JMC-MWSP-W-DI-MST-R 00
 Quality Management System Job Code:
Project Quality Plan, Issue: Rev: 00
JMC PROJECTS (INDIA) LIMITED
Document No. Date :24.11.2020
JMC-MWSP-W-DI-MST-R-00
Client: Ministry of National Planning, Housing and Infrastructure, Govt. of the Page 10 of 19
Republic of Maldives.

6.13 Jointing of Pipes:Two main types of joints are used with ductile iron pipes and
fittings:
I. Socket and spigot flexible joints:
1. Push on joints;
2. Mechanical joints;
II. Rigid flanged joint.
I. Flexible Joint
It incorporates gasket of elastomeric materials and the joints may be of the simple
push-on-type or the type where the seal is affected by the compression of a rubber
gasket between a seating on the inside of the socket and the external surface of
spigot. Joints of the latter type are referred to as mechanical joints. Both push-in
(See fig. 5A) 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.
The DI pipes shall be push-on joined using socket and spigot type ends by placing
EPDM rubber gaskets between them.

fig - 5 A
Thoroughly clean the spigot and the interior of the socket. Clean gasket and insert
into socket with the square section gasket heel in the retaining groove and the
gasket fish tail towards the back of the socket.
Gasket should be kept in dark place (avoid sunlight), before using, it should be
ensured that there is no deformation and damage in gasket.
The insertion of gaskets is facilitated by folding the gasket as shown in (fig:5 A) by
looping it into a heart shape with the gasket fish tail towards the back of the socket
Apply radial pressure to the gasket at the heart shaped loop (or cross loops) to force
it into place. Check that the gasket is located correctly around its entire
circumference with the retaining heel firmly embedded in its seating. Apply a thin
film of lubricant (vegetable Grease) to the inside surface of the gasket and to the
outside surface of the spigot. Lubricant shall be a vegetable / food grade. Document
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Project Name: MWSP, Maldives.
DOC No: JMC-MWSP-W-DI-MST-R 00
 Quality Management System Job Code:
Project Quality Plan, Issue: Rev: 00
JMC PROJECTS (INDIA) LIMITED
Document No. Date :24.11.2020
JMC-MWSP-W-DI-MST-R-00
Client: Ministry of National Planning, Housing and Infrastructure, Govt. of the Page 11 of 19
Republic of Maldives.

evidence is required. Support the pipe or fittings just clear of the trench bottom and
enter spigot into socket until contact is made. Push fit joints have the capability of
permitting both angular deflection and longitudinal movement within defined limits.
Joint Assembly:
 Crowbar DN80 and DN 150: - Push against the end of the pipe socket face with
a crowbar or lever to complete the joint (see fig. a) below.
 Chain Pulley DN80 to DN 500: - Where suitable equipment is available on site
joints can be made using the Chain Pulley. This method minimizes the human
effort required to make a joint and is widely used. Using this method, higher
Diameter Pipes can be joined properly. The pipes are locked using Chain pulley
(see fig-b). And by to-and-fro motion of the lever, pipes are slowly and steadily
joint each other and made to the correct insertion depth.

 Other Methods: -Rack and lever, side-link tackle and hydraulic tackle can also
be used to joint integral pipes.
After successfully inserted the spigot, the joint should be thoroughly checked
whether it is correctly seated. This is done by inserting the metal rule into the socket
gap. If the depth of penetration is same circumferentially, then joint is ok. Any
difference in depth of penetration if found, the gasket may be displaced which prone
for leaking during hydro testing.
II. Flanged Joint
Flanged joints are made on pipes having a machined flange at each end of the pipe.
The seal is usually effected by means of a flat rubber gasket compressed between
two flanges by means of bolts which also serve to connect the pipe rigidly (see fig
5B). Gaskets of other materials, both metallic and non-metallic, are used for special
applications.

P a g e | 11
Project Name: MWSP, Maldives.
DOC No: JMC-MWSP-W-DI-MST-R 00
 Quality Management System Job Code:
Project Quality Plan, Issue: Rev: 00
JMC PROJECTS (INDIA) LIMITED
Document No. Date :24.11.2020
JMC-MWSP-W-DI-MST-R-00
Client: Ministry of National Planning, Housing and Infrastructure, Govt. of the Page 12 of 19
Republic of Maldives.

6.14 Jointing Procedure

Procedure for jointing shall vary according to the type of joint being used. Basic
requirements for all types are:
 Cleanliness of all parts,
 Correct location of components,
 Centralization of spigot within socket, and
 Strict compliance with manufacturer’s jointing instructions.
The inside of sockets and the outside of spigots shall be cleaned for a distance of
150 to 225 mm.
Glands and gaskets shall be wiped clean and inspected for damage.
When lifting gear is used to place the pipe in the trench, it shall also be used to
assist in centralizing the spigot in the socket.
The lubricant has to have the following characteristics:
 Must have a paste like consistency and be ready for use
 Has to adhere to wet and dry surfaces of DI pipes and rubber rings
 To be applied in hot and cold weather; ambient temperature 0 - 50 °C,
Temperature of exposed pipes up to 70 °C
 Must be non-toxic
 Must be water soluble
 Must not affect the properties of the drinking water carried in the pipes
 Must not have an objectionable odor
 Has to inhibit bacterial growth
 Must not be harmful to the skin
 Must have a shelf live not less than 2 years

Note: No petroleum lubricants should be used as it deteriorates the rubber gasket.

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Project Name: MWSP, Maldives.
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Client: Ministry of National Planning, Housing and Infrastructure, Govt. of the Page 13 of 19
Republic of Maldives.

 Insertion of Rubber Gasket

i. Clean the inside of the socket where gasket heel is to be inserted using a wire
brush and a rag. Carefully clean the inside of the socket particularly the gasket
recessed. In particular, remove any deposits of earth, sand etc.(fig 1)

ii. Clean gasket and insert into socket with the square section gasket heel in the
retaining grove (fig 2)

iii. Coat with lubricating paste on the spigot end of the pipe and the exposed surface
of gasket. The gasket recess must not be coated with lubricating paste, except
for small diameter pipes or fitting when problems arise on fitting the gasket(fig 3)

Joint Assembly:

 Prepare & lubricate the joint area & place pipe / fitting in position, ready for jointing.

P a g e | 13
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Republic of Maldives.

 Hold the socket end of the fitting with crowbars slightly dug into the ground and
anchored at the ears provided in the socket. Push the crowbar in a jerk
simultaneously. (See fig 1 & 2). Pipe socket face must be protected with a piece of
hard wood.
6.15 Valve Installation
All valves, gates, operators and appurtenances shall be installed with proper flow
direction in accordance with the approved drawings as per the specifications laid for
pipe laying to the locations indicated on the drawings. The installation shall be true
to alignment and rigidly supported. The nominal size and thickness of the flanges
shall be as defined for pressure rating conforming to IS 14486 /14845 PN 1.6.The
pressure rating of the flanges shall be equivalent to the valve with which they are
being installed. The selection of the flange out of these three ratings shall be based
on the design pressure at the place of installation
Valves shall be flanged and the flange face at right angles to the valve centerline.
Backside of valve flanges shall be machined or spot faced for proper seating of the
head and nut. Nuts and bolts shall be of the best quality bright steel, machined on
the shank and under the head and nut. Studs, bolts and nuts shall be galvanized.
Bolts shall be of accurate length so that only one thread shall show through the nut
in the fully tightened conditions. Grade of nuts and bolts shall be conforming to IS
1363:2002.
Throughout erection, the valves shall be supported properly on wooden sleepers,
etc. and shall be concreted immediately thereafter, as directed. Before the valves
are actually fixed, they shall be cleaned and greased and it should be seen that all
parts are in perfect working condition.
The hand wheels shall be provided with extension for easy grip. All operators when
fitted to the valve shaft must ensure clockwise closing and this must be indicated on
the housing.
6.16 Hydrostatic Testing:
After a new pipe line has been laid, jointed and back filled, it shall be subjected to
pressure test to ensure that pipes and joints are sound enough to withstand the
maximum pressure likely to be developed under working condition.
The test pressure should not be less than the following:
 The maximum sustained operating pressure
 The maximum static pressure + 0.5 N/mm2
 The maximum sustained operating pressure (or the maximum static pressure) +
Maximum calculated surge pressure.

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Project Name: MWSP, Maldives.
DOC No: JMC-MWSP-W-DI-MST-R 00
 Quality Management System Job Code:
Project Quality Plan, Issue: Rev: 00
JMC PROJECTS (INDIA) LIMITED
Document No. Date :24.11.2020
JMC-MWSP-W-DI-MST-R-00
Client: Ministry of National Planning, Housing and Infrastructure, Govt. of the Page 15 of 19
Republic of Maldives.

At the lower end the Calibrated pressure gauge and the connection to the pump
shall be established for testing the test pressure at the higher end with a valve for
air outlet.
If the pressure gauge cannot be installed at the lowest point of the pipeline, an
allowance in the test pressure to be read at the position of the gauge has to be made
accordingly
6.17 Pressure testing equipment: The test equipment’s shall be used
 A suitable main pump for attaining the required pressure.
 Calibrated pressure gauge with a range of 1.5 to 2 Times of testing pressure
(Calibration interval of pressure gauge shall be 6 months) If the range is not
available then it shall be 1.5 to 4 times
 Flow regulating valve or Scour Valve for depressurizing of pipe line.
 Stopwatch
 Suitable stub ends, slip-on flanges, blank flanges fitted with drain valve, non-
return valve, necessary hoses of adequate pressure rating and couplers etc.
6.18 Sequence of Testing
 The testing scheme shall be submitted to client prior to test.
 For testing of pipe section, clean construction water shall be used.
 Flushing shall be done before the start of hydro test through line scour valve.
 During filling of water proper venting shall be done at highest point to remove all
the entrapped air Calibrated pressure gauge, one at pressurizing point and one
in end point shall be installed during testing.
 First the test pressure in the pipe line section is raised from zero pressure to the
Nominal pressure or working pressure and hold for one hour.
 The test pressure shall be measured at the lowest point of section under test or
suitable allowance on static head shall be made to ensure the test pressure does
not exceed the required test pressure.
 The test pressure shall be applied and maintained for one hour. The minimum
test period shall not be less than 10 minutes.
 If the visual inspection satisfies and there is no leakage in the pipes and joints
the test can be considered as passed.
 If there is pressure drop during the test, water shall be pumped in to sufficiently
equalize the drop in pressure. The amount of water pumped in shall be carefully
measured in order to measure the leakage.
 The area of defect shall be identified and repaired suitably, and the test shall be
repeated for the satisfaction of Engineer In-charge.
 Readings at the location of the Pressure gauge to be noted during the testing
and the reading are tabulated
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Project Name: MWSP, Maldives.
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Republic of Maldives.

 After completing the test, the ends shall be covered with dummies to ensure no
foreign particles shall be entered to the pipeline.
6.19 Back filling of Trenches
The excavated earth can be used to fill trench in layers with proper tamping. Taking
due care so that no damage is caused to the pipes.
7.0 Quality assurance
 QA/QC personal shall check the materials at the receipt, storage and before use to
ensure Specifications Compliance.
 DI Pipe size Dimension, Thickness shall be checked as per drawing and as per
inspection report.
 DI Pipe Excavation, laying and jointing shall be checked as per code and
specification.
 Both side gap of DI pipe should be 150 to 200 mm.
 DI Pipe alignment shall be checked as per code and specification.
 Hydro Test shall be checked as per approved drawing, specification and code.
 Trench cover should be ensured 900-1100 mm.
8.0 Health and Safety
The health safety and environment Management plan institutes the overall
mechanism for the risk management process with regard to the project. As an
integral part of the planning process prior to commencement of any operational
activity a suitable and sufficient specific assessment of risk associated with the
works should be done.
8.1 Training
Quality orientation training, Pep talk and HSE Induction training based on site
requirement shall be provided to all personnel to work in the site.
Job specific training shall be provided to the working personnel:
 JCB operators
 Pipe Laying team
 Hydro Test team
 All work force related to the Activity
 First aiders

P a g e | 16
Project Name: MWSP, Maldives.
DOC No: JMC-MWSP-W-DI-MST-R 00
 Quality Management System Job Code:
Project Quality Plan, Issue: Rev: 00
JMC PROJECTS (INDIA) LIMITED
Document No. Date :24.11.2020
JMC-MWSP-W-DI-MST-R-00
Client: Ministry of National Planning, Housing and Infrastructure, Govt. of the Page 17 of 19
Republic of Maldives.

8.2 Risk Assessments

 HSE Hazards involved in the activities, tasks, tools & equipment pertaining to this
job shall be assessed through Hazards & Effects Management Process (HEMP)
for each and every activity.
 The contents in HEMP Register shall be disseminated within the crew by the shift
supervisor / foreman, through Toolbox Talk.
 Any new hazards & controls identified with reference to site conditions change
shall be briefed to the crew by the supervisor / Foreman, prior to commencement
of any activity.
 Following control measures generally apply to all hazards that shall be adopted
as a proactive measure in addition to the specific controls identified in the HEMP
Register:
 Correct use & maintenance of tools and equipment.
 Third party inspection of all tools / tackles and crane.
 Deployment of trained & authorized persons for the job.
 Conduct of toolbox talks prior to work commencement.
 Provision of adequate warning signs, barricading, etc.
 Good Housekeeping.
 Adequate and effective supervision.
 Use of necessary PPE.
 Prevention of Inhalation of Toxic chemicals, Solvents.

8.3 Personal Protective Equipment (PPE): Personal Protective Equipment provided

to employees are as listed below:
 Helmet, Safety Shoes, Safety Goggles, Dust Mask, Ear Plugs, Coverall &
reflective vests .
 Hand Gloves (Rubber gloves) – for all during manual handling of materials.
 Use of Respirators/ Half mask in the areas of Hazardous fumes exposure /
while chemical spraying.
8.4 First Aid / Medical Facility / Fire Fighting:
 Availability of First Aiders (with ready access to first aid boxes) shall be ensured
at each worksite. A first aid box with recommended items shall be kept at the work
place for use in case of requirement.
P a g e | 17
Project Name: MWSP, Maldives.
DOC No: JMC-MWSP-W-DI-MST-R 00
 Quality Management System Job Code:
Project Quality Plan, Issue: Rev: 00
JMC PROJECTS (INDIA) LIMITED
Document No. Date :24.11.2020
JMC-MWSP-W-DI-MST-R-00
Client: Ministry of National Planning, Housing and Infrastructure, Govt. of the Page 18 of 19
Republic of Maldives.

 Medical facility for the crew when in need, shall be utilizing the clinic / hospital
identified for the purpose.
 List of First Aider/Fire Fighting Team shall be displayed.
 An exclusive Emergency Vehicle shall be provided, for any eventuality.

8.5 Cleaning Procedure of Worksite

 Saw dust and concrete wastage collected in Designated – marked container for
disposal at designated waste disposal facility.
 Washed water from hard surface floors shall not be sent to sewer and to be
collected in a plastic container, labeled & stored for suitable disposal action.
 Safe Storage System shall be practiced & Handling is ensured by trained
personnel only.
 Appropriate PPEs (Rubber gloves etc.) shall be used while doing handling,
cleaning activity.

8.6 Hygiene at Workplace:

 To help, minimize the spread of viruses / dermatitis and upkeep of good health of
the employees, it is important to follow proper hygienic practices some practices
and procedures that will help reduce risk include:
 Wash hands frequently. This is one of the most basic and important preventative
measures could be taken against the flu and some other viral diseases. Use
warm soapy water and wash hands for 15-20 seconds,
 Before and after food preparation or eating.
 After removing personal protective equipment, such as masks and gloves.
 After use of rest rooms / toilets.
 Keep the work areas clean.
 These tips are based on recommendations from organizations such as the World
Health Organization and the Centre for Disease Control.
 All the above points are disseminated to the site personnel through Special Tool
Box talk periodically.
 Replacement of PPE`s shall be ensured, based on the Task, usage & Damage.

P a g e | 18
Project Name: MWSP, Maldives.
DOC No: JMC-MWSP-W-DI-MST-R 00
 Quality Management System Job Code:
Project Quality Plan, Issue: Rev: 00
JMC PROJECTS (INDIA) LIMITED
Document No. Date :24.11.2020
JMC-MWSP-W-DI-MST-R-00
Client: Ministry of National Planning, Housing and Infrastructure, Govt. of the Page 19 of 19
Republic of Maldives.

8.7 Emergency Response procedure:

 The MSDS shall be kept at site for reference and use in case of emergency.
 Adequate signage shall be ensured related to the task performed.
 Chemical exposed personnel shall be moved out of the spot to a safe location.
First aid shall be given in line with the MSDS guidance.
 If required, body wash shall be given within the site using copious amount of
water.
 In the event of contact to Eyes, the Portable eye washer shall be used to wash
the eyes.
 Call for help within the worksite by calling the 24 Hrs. Emergency no.
 Respond to the emergency of containing the spill, etc. - if trained and if safe to
do so. Else call for help through 24 Hrs. emergencies and wait for further help
from external assistance.
 Remove the affected personnel from the location to a fresh air place & call for
assistance to shift him / her to the nearby identified Hospital for further treatment.
 The Crew in-charge shall ensure that crew members have ready access to the
telephones for use during emergencies and the emergency contact numbers are
displayed in the site.
 The emergency actions to follow to be disseminated to the work group through
daily tool box talk and ensured of the understanding by one and all.
 Extreme requirements, call “XXXX” for POLICE/Emergency Response Team /
Ambulance assistance.
9.0 Environmental conservation
Care shall be taken in line with the environmental requirements. During use
recycling and reuse of material shall be promoted with due approval from engineer
in-charge.

10.0 Attachments
 Procured Material MTC from Vendor/Supplier
 Inspection Request (RFI)
 Pipe Laying Recorded with chain age in register.
 Hydro Test Report

P a g e | 19
Project Name: MWSP, Maldives.
DOC No: JMC-MWSP-W-DI-MST-R 00