QUALITY MANUAL

MISCL- QMCP-0001-2012 REV. 0, Volume 2 1

ISSUED DATE: 12 Jan. 2012

Document Title :
Approved Checked Originator
Revision / Civil Works Quality Construction
Establishment Procedures Abdullah Omar Ramil G.
No of Al- Ofi Abdullah Makiling
Description :
Revision SITE NON-ELECTRICAL
Managing Construction QA / QC
Implementation Document No : MISCL – QCCP – 0012 Director Manager Engineer
Date
Contents / Reason for Revision

Jan.12, 2012
0 Establishment and Implementation
Jan.13, 2012

This document is the property of Makana and no parts of this document shall be reproduced by any
means without prior approval by the company.

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PROCEDURE FOR
SITE NON-ELECTRICAL UTILITIES

Table of Contents

Index Page

1.0 Scope 3

2.0 Purpose 3

3.0 References 3

4.0 Definitions 3

5.0 Responsibilities 3

6.0 Procedure 3

7.0 Documentation 9

1.0 Scope

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This quality procedure applies to the installation of Fire/Raw Water, Drinking Water,
and Sanitary Sewer, piping, fittings, accessories, bedding and connections.

2.0 Purpose

The purpose of this quality procedure is to provide a procedure for the installation of
all site Non-Electrical Utilities.

3.0 References

Construction Specifications & IFC Drawings.

4.0 Definitions

None

5 .0 Responsibilities

5.1 The discipline supervisors and/or foremen are responsible for the
installation activities assuring all works being implemented are in
Conformance with specifications and approved drawings.

5.2 The discipline QC Inspectors shall ensure that approved quality control
Procedure is implemented throughout the course of the installation.
Inspection shall be done on materials or work, which will be incorporated
to the system. They shall coordinate with Company Representative regarding the
inspection and testing activities. Documentation of all inspection and test made
shall also be their responsibility.

6.0 Procedure

6.1 General Requirements:

6.1.1 Thermoplastic and RTR pipes, fittings and accessories shall be stored and
handled in accordance with manufacturer’s recommendation and the requirements of
the Standard Operating Procedures

6.1.2 Concrete requirements shall be in accordance with work procedure MISCL-

QCCP-0005, Concrete Works.

6.1.3 Excavation, Trenching, Backfilling and Compacting shall be carried out in

accordance with work procedure MISCL-QCCP-0003, Excavation, Trenching,
Backfilling and Compacting, and as herein specified.

6.1.3.1 All excavations shall be restored so its surface contour blends in with

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the surrounding area. All existing pavements (asphalt and concrete) disturbed
during trenching operation shall be restored to their original condition or
better.

6.1.3.2 No construction shall start until the design of the dewatering system (if
required) has been approved by the Company Representative. Dewatering
shall be carried out in accordance to Method Statement submitted by
Dewatering Sub-Contractor and approved by Company Representative.

6.1.3.3 The bottom of the trench shall be dry before pipe is installed.

6.1.3.4 At the end of every work shift, personnel performing the pipe
installation shall ensure that the pipe ends are capped to prevent the egress of
foreign material and the piping is anchored to prevent floatation.

6.1.3.5 The depth of the trench shall be dug deep enough to provide a
minimum ground cover above the top of the pipe as required and a ground bed
of at least 150 mm in depth below the bottom of the pipe.

6.1.3.6 The width of the trench should be wide enough to allow room for
jointing.

6.1.3.7 The ground bed shall provide uniform and adequate support and
drainage along the entire length of the piping. In sabkha areas, a base support
layer of crushed stone base material 150 mm deep – 38 mm maximum size
shall be provided. The crushed stone base material shall be compacted to at
least 95% of ASTM D698.

6.1.3.8 A bedding layer of clean sand, 150 mm in depth is required for all
trenches. The sand shall be free of debris and rocks and compacted to at least
70% relative density, or 95% proctor density as per ASTM D698, whichever
gives the greater density.

6.1.3.9 The trench bottom shall be continuous, smooth, free of rocks, and to
the line and grade shown on the installation drawings. The pipe shall have
essentially continuous support and not rest on the joint. For RTR piping, the
trench contour shall not cause the joint angular deflection or the pipe-bending
radius to exceed the manufacturer’s limit.

6.1.3.10 The minimum trench width from the bottom to 300 mm above the top
of the pipe shall be as per Company/Client’s Standards and Specifications.

6.1.3.11 Trenches maybe excavated wider than the trench width above the
LNTL (Line of Narrow Trench Limit), if necessary.

6.1.3.12 Sheeting or shoring shall be in accordance with the Company

Construction Safety Manual, Section II. All underpinnings, bracings, and

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shoring shall be provided as necessary to protect and preserved all existing

buildings, fences, walls, utilities, and other structures.

6.1.3.13 The minimum cover over the top of the pipe shall be as per
Company/Client’s Standards and Specifications.

6.1.3.14 Piping shall have steel sleeves at government road crossings and
railroad crossings in accordance with the Company Standards and
Specifications.

6.1.3.15 If it is impossible to achieve the minimum cover as specified in this

Standard, the piping shall be protected by a reinforced concrete slab, or
metallic casing in accordance with the Company Standards.

6.1.3.16 The trench bottom shall be continuous, smooth, free of rocks, and to
the line and grade shown in the installation drawings. The pipe shall have
essentially continuous support and not rest on the joint. For RTR piping, the
trench contour shall not cause the joint angular deflection or the pipe-bending
radius to exceed the manufacturer’s limit.

6.2 Assembly and Installation

6.2.1 All pipes shall be installed in accordance with IFC Drawings,

Construction Specification and applicable provisions of the Company
Standards and Specifications.

6.2.1.1 Pipes and fittings shall be inspected before installation to detect

defects. Defective materials shall be marked with paint and promptly
removed from the site.

6.2.1.2 When placing pipe in the trench, fabric slings shall be used.
The pipe shall not be dragged along the bottom of the trench, nor
humped, and it shall be supported by the sling while being fitted to the
adjacent pipe. No metal tools or heavy objects should be permitted to
come into unnecessary contact with the pipe or fittings.

6.2.1.3 The pipe shall be laid at the level and gradient stipulated, on a
prepared bed 150 mm deep with special hollows made for the joints.
The pipe shall be aligned carefully in both the horizontal and vertical
planes. Pipe shall be uniformly bedded throughout its length.

6.2.1.4 Every precaution shall be taken to prevent foreign matter from

entering the pipe or fittings. During laying operations, no debris, tools,
cloth or other materials are to be allowed to enter the pipe.

6.2.1.5 Deflection at joints shall not exceed the maximum

recommended by the manufacturer.

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6.2.1.6 As the work progresses, interior of the pipe shall be cleared of

dirt and other foreign material.

6.2.1.7 The bottom of the trench shall be dry before pipe is installed.

6.2.1.8 At the end of every work shift, pipe ends shall be sealed by
temporary watertight plugs to prevent the egress of foreign material.

6.2.1.9 The minimum clear distance between raw and drinking water
lines, if installed in the same trench, shall be 300 mm.

6.2.1.10 All water supply piping shall have a minimum cover of 24 in.
(610 mm) for all pipes 3 in. (90 mm OD) diameter and larger; and 12
in. minimum cover (305 mm) for smaller than 3 in. (90 mm OD) pipes.

6.2.1.11 Underground parallel water supply and fire water piping shall
have a minimum horizontal clear distance of 12 in. (305 mm).

6.2.1.12 A branch piping of a raw/firewater combined distribution

system, serving firewater systems of a building or a facility shall be
connected upstream of the isolation valve of the raw water supply
piping.

6.2.2 RTR Piping

6.2.2.1 The installation of RTR piping shall be done by personnel

trained in the proper handling and usage of applicable materials and
equipment.
6.2.2.2 Adhesive-bonded RTRP Joints shall be assembled in
accordance with the manufacturer’s procedures. Heating blankets shall
be used to cure adhesive bonded RTRP joints.

6.2.2.3 RTR piping of 250 mm nominal pipe size and less may be
assembled next to, or in the trench. Piping larger than 250 mm nominal
pipe size shall be assembled in the trench.

6.2.2.4 For trenches 2 M deep or less, pipe assembled next to the

trench shall not be moved within three pipe lengths of an uncured joint.
The pipeline shall be lowered into the trench progressively to avoid
excessive joint angular deflection.

6.2.2.5 For trenches deeper than 2M, pipe shall be assembled in the
trench.

6.2.2.6 Pipe and fittings shall not be dropped into trench. Protect from
all types of impact and excessive overheating causing deformation or
permanent damage to pipe.

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6.2.2.7 Bedding in the pipe zone should be clean sand. Sand bedding
under the pipe should be a minimum of 150 mm in thickness.

6.2.2.8 Sand shall be uniformly compacted around the pipe with

particular care given to the bedding beneath the haunches of the pipe.
Sand may be compacted by hydraulic methods if the native soil in
which the trench is excavated is free draining. If trench is not free
draining, placement of damp sand will facilitate compaction. Sand
bedding and backfill should extend a minimum of 300 mm above the
pipe.

6.2.2.9 Backfill shall be deposited in 150 mm maximum layers to a

point at least 600 mm above the top of the pipe, each layer being
compacted as required.

6.2.2.10 In-place tests of soil density shall be made in accordance with

ASTM D1556 or ASTM D2167.

6.2.2.11 Mechanical compactors may be used provided harmful shock

loads are not transmitted to the pipe. Maintaining a space of at least
one foot between tamping feet and pipe wall should avoid damage to
the pipe wall.

6.2.2.12 The minimum earth cover above the pipe crown shall be 900
mm (3ft).

6.2.3 Thermoplastic Piping

6.2.3.1 Before any pipe or fitting is lowered into the trench it shall be
carefully checked to ensure that it is not cracked or damaged in any
way. Damaged pipe shall either be cut, so that flawless pipe is obtained
with the least possible waste.

6.2.3.2 Joints shall be made in accordance with ASTM D2855. Solvent

cement shall conform to ASTM D2564.

6.2.3.3 After the pipe has been made, the piping shall not be moved
until the drying time has elapsed. To limit movement of a pipe string,
the first pipe shall be backfilled with the joint exposed.

6.2.3.4 Pipe shall not be exposed to direct sunlight and provisions shall
be made for shading any pipe which is left in the open or uncovered in
trenches.

6.2.3.5 Sewer pipe shall be laid beginning at the low point of the
system, true to the grades and alignment indicated with unbroken
continuity of invert. Pipes shall be placed with bell ends facing

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upstream.

6.2.4 Water, Sewer Location and Crossing

6.2.4.1 No sewer main shall be located closer in a horizontal direction,

than 3M to a water main.

6.2.4.2 Where a sewer main or lateral cross below a water main or

water service line, the sewer line shall in all cases be installed at least
30cm below the water line.

6.2.4.3 Where the water main, or service line crossing above the sewer
line or lateral has less than 30cm vertical distance, the sewer pipe shall
be fully encased with 150mm thick of concrete all around for a
distance of 3M each side of the crossing (measured perpendicular from
the water main or service line).

6.2.4.4 The sewer main or laterals may cross above a water main or
water service line with the approval of Company Representative. In
such a case, the sewer pipe shall be fully encased with concrete.

6.2.4.5 Where a water or sewer line crosses electrical or telephone

cables, approval from the concerned authorities shall be obtained.

6.2.4.6 The minimum crossing or parallel clearance between direct

buried cables or conduits and underground piping, including
hydrocarbon pipelines shall be 30cm (12 in.).

6.2.4.7 Sewer lines passing through roads and pavements having cover
less than 900mm shall be sleeved or concrete encased.

6.2.4.8 Parallel building sewers and water service lines, if necessary,

may be laid in a common trench provided that all of the following
requirements are met:

6.2.4.8.1 The bottom of the water pipe(s), at all points, shall be at least
12 in. (305mm) above the top of the sewer line.

6.2.4.8.2 The side(s) of the water pipe(s), at all points, shall be at least
12 in. (305mm) clear horizontally from the side of the sewer line.

6.2.4.8.3 The water pipe(s) shall be placed on a solid shelf of the

common trench, or the water line shelf be of select backfill compacted
to a minimum of 95% density as per ASTM D698.

6.2.4.9 Company Representative shall be notified before any

connection is made to the existing system. Elevation of existing pipes

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shall be field verified at tie-in points prior to construction.

6.2.4.10 Adapter coupling/flange shall be provided at tie-in points as

required.

6.3 Pressure Testing

6.3.1 Pressure Testing, inspection and repair in case of any leakages during
hydro test shall be carried out in accordance with Work Procedure MISCL-
QCCP-0010, Pressure Testing.

6.3.2 Underground piping shall be partially backfilled with all joints exposed
during the hydro test. The exposed joints shall be shaded from direct sunlight,
and the hydro test shall be performed so that the temperature of the
thermoplastic piping material or the temperature of the test water does not
0
exceed 40 C during the test period.

7.0 Documentation

None

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