Work Method of Statement

for HDPE lining Installation and Testing

Contents

1. PERPOSE ............................................................................................................................................................. 1
2. REFERENCES...................................................................................................................................................... 1
3. SCOPE ................................................................................................................................................................. 1
4. HSE ....................................................................................................................................................................... 1
5. RESOURCES........................................................................................................................................................ 1
6. METHOD.............................................................................................................................................................. 3
7. FIELD QUALITY CONTROL ............................................................................................................................. 4

Aldahham, HDPE Geomembrane Installation and Testing

 Work Method of Statement
for HDPE lining Installation and Testing

1- Purpose:
The purpose of this Work Method Statement is to describe step by step the procedure for all
activities to achieve the best HDPE geomembrane lining installation results. This document
aims to ensure that works are carried out within safe conditions and within applicable
requirements.
2-References
 DVS (German Welding Society) 2202-3.
 GSE work method Statement.
 ASTM D 4437.
 Shell Iraqi Petroleum Development HSE rules.

3- Scope:

This procedure applied to all Al Dahham facilities which have more than 6 years experience in
HDPE membranes lining and installed more than 500 000 , Republic of Iraq and to all
personnel whether employed by Al Dahham Group and sub-contractor personnel at Al Dahham
controlled area and visitors such as enforcement agencies of the government, material
suppliers etc.

Scope includes:
 Cleaning the work area.
 Choosing the suitable way for lining
 Welding and marking
 Testing and repairing then test again.
 Reporting.

4- HSE (Health and Safety Executive)

For any work the most important thing is the HSE , for achieving Goal Zero we should follow
below issues :
 PPE should be equipped
 Using suitable and checked equipments.
 Method of Statement (MOS)
 Job Hazard Analysis (JHA )
 Permit to Work (PTW)
 Trained staff.
5- Resources

A . Manpower:
 Construction Manager …………………….1
 Construction Supervisor ………………….1
 HSE Supervisor ……………………………1
 Welders ……………………………………..3
 Skill laborer …………………………………9
 Drivers ………………………………………3
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Aldahham, HDPE Geomembrane Installation and Testing
 Work Method of Statement
for HDPE lining Installation and Testing

B . Equipment
 Hot Wedge welding machine
 Extrusion Machine
 Hot air blower
 Examometer ( distractive test device )
 Coupon cuter
 Pressure test instrument
 Vacuum tester
 Spark tester device
 Generator
 Rolls
 Clamp tools
 Cutters
 Marker
 Sand paper
 Rope stairs

C . Materials
 HDPE Geomembrane liner
 HDPE rod

6- Method

HDPE sheets installation:

Manually clean the working area before starting the daily work to be sure that there is no
any big size stone or metal pieces that will damage the sheets.
The general and/or Earthwork Contractor shall be responsible for preparing and maintaining
the subsoil in a condition suitable for installation of the liner unless specifically agreed
otherwise. Surfaces to be lined shall be smooth and free of debris, roots and angular or
sharp rocks. All fill shall consist of well-graded material, free of organics, trash, clay-balls, or
other deleterious material that may cause damage to the geomembrane. The subsoil shall
be compacted in accordance with design specifications, but in no event less than is required
to provide a firm unyielding foundation sufficient to permit the movement of vehicles and
welding equipment over the subsoil without causing rutting or other deleterious effects. The
subsoil shall have no sudden sharp or abrupt changes in grade.
Handel each HDPE roll with care and put it on a proper stand to make it easy to un roll the
material and start the outstretching of the sheet over the working area and be sure that each
roll cover the desired workplace with an overlap of 14-15 cm between the sheets.

HAVE TO NOTE:
No geomembrane material shall be unrolled and deployed if the material temperatures are
lower than 0 degrees C (32 degrees F)and not more than 75 degree C ,unless otherwise
approved by the Owner's Representative. The specified minimum temperature for material
deployment may be adjusted by the Owner’s Representative .Temperature limitations
should be defined in the preconstruction meeting. Typically, only the quantity of
geomembrane that will be anchored and seamed together in one day should be deployed.
Geomembrane placement shall not be done if moisture prevents proper sub grade
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Aldahham, HDPE Geomembrane Installation and Testing
 Work Method of Statement
for HDPE lining Installation and Testing

preparation, panel placement, or panel seaming Moisture limitations should be defined in

the preconstruction meeting.

1. Due to the change of the environment condition on daily bases (e.g. temperature and
humidity) a pre fusion welding test procedure must occur on a sample of the HDPE to
calibrate the welding machine to insure final good results. this procedure must apply on
daily bases or if there is a change in the temperature of 5 degree or more.

2. After the calibration (temperature, pressure and speed) of the machine the fusion welding
start automatically from one end to the other, two trained persons walk with the machine the
first monitor the machine performance the other clean the overlapped parts of the sheets
with a dry cloth to be sure that there is no dirt that will cause welding failure . As a result of
the welding action two welded parts will appear on the overlapped parts with a mid air
tunnel that will used later for the pressure test.

3. In some cases the fusion welding is un applicable an alternative method of extrusion fillet
welding will be used either to weld two pieces directly or by using a third piece as a patch.

7- Field Quality Control

The Owner’s Representative shall be notified prior to all pre qualification and production
welding and testing, or as agreed upon in the pre construction meeting.

A. Prequalification Test Seams.

1. Test seams shall prepare and tested by the Geomembrane Installer to verify that
seaming parameters (speed, temperature and pressure of welding equipment) are
adequate.
2. Test seams shall be made by each welding technician and tested in accordance
with ASTM D 4437 at the beginning of each seaming period. Test seaming shall be
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Aldahham, HDPE Geomembrane Installation and Testing
 Work Method of Statement
for HDPE lining Installation and Testing

performed under the same conditions and with the same equipment and operator
combination as production seaming. The test seam shall be approximately 3.3
meters (10 feet) long for fusion welding and 1 meter (3 feet) long for extrusion
welding with the seam centered lengthwise. At a minimum, tests seams should be
made by each technician 1 time every 4–6 hours; additional tests may be required
with changes in environmental conditions.
3. Two 25 mm (1 in) wide specimens shall be die-cut by the Geomembrane Installer
from each end of the test seam. These specimens shall be tested by the
Geomembrane Installer using a field Tensiometer (as shown below ) testing both
tracks for peel strength and also for shear strength. Each specimen should fail in the
parent material and not in the weld, “Film Tear Bond"(F.T.D. failure). Seam
separation equal to or greater than 25% of the track width shall be considered a
failing test.

Tensiometer

4. If a test seam fails, an additional test seam shall be immediately conducted. If the
additional test seam fails, the seaming apparatus shall be rejected and not used for
production seaming until the deficiencies are corrected and a successful test seam
can be produced.
5. A sample from each test seam shall be labeled. The label shall indicate the date,
geomembrane temperature, number of the seaming unit, technician performing the
test seam and pass or fail description. The sample shall then be given to the
Owner's Representative for archiving.

B. Field Seam Non-destructive Testing (NDT).

1. All field welded seams and non-welded area shall be non-destructively tested by the
Geomembrane Installer over the full seam length and non-welded area before the
area are covered. Each seam shall be numbered or otherwise designated. The
location, date, test unit, name of tester and outcome of all non-destructive testing
shall be recorded and submitted to the Owner's Representative.

2. Testing should be done as the seaming work progresses, not at the completion of all
field seaming, unless agreed to in advance by the Owner's Representative. All
defects found during testing shall be numbered and marked immediately after
detection. All defects found should be repaired, retested and remarked to indicate
acceptable completion of the repair.

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Aldahham, HDPE Geomembrane Installation and Testing
 Work Method of Statement
for HDPE lining Installation and Testing

3. Non-destructive testing shall be performed using vacuum box, air pressure and spark
testing equipment.

4. Non-destructive tests shall be performed by experienced technicians familiar with the

specified test methods. The Geomembrane Installer shall demonstrate to the
Owner's Representative all test methods to verify the test procedures are valid.

5. Extrusion seams shall be vacuum box tested by the Geomembrane Installer in

accordance with ASTM D 4437 and ASTM D 5641 with the following equipment and
procedures:
a. Equipment for testing extrusion seams shall be comprised of but not limited to:
a vacuum box assembly consisting of a rigid housing, a transparent viewing
window, a soft rubber gasket attached to the base, port hole or valve assembly
and a vacuum gauge ( as shown below); a vacuum pump assembly equipped
with a pressure controller and pipe connections; a rubber pressure/vacuum
hose with fittings and connections; a plastic bucket; wide paint brush or mop;
and a soapy solution.

Vacuum Box
b. The vacuum pump shall be charged and the tank pressure adjusted to
approximately 35 Kpa (5 psi).
c. The Geomembrane Installer shall create a leak tight seal between the gasket
and geomembrane interface by wetting a strip of geomembrane
approximately 0.3m (12 in) by 1.2m (48 in) (length and width of box) or by
using circular vacuum box with 32 cm diameter with a soapy solution, placing
the box over the wetted area, and then compressing the box against the
geomembrane. The Geomembrane Installer shall then close the bleed
valve, open the vacuum valve, maintain initial pressure of approximately 35
Kpa (5 psig) for approximately 5 seconds. The geomembrane should be
continuously examined through the viewing window for the presence of soap
bubbles, indicating a leak. If no bubbles appear after 5 seconds, the area
shall be considered leak free. The box shall be depressurized and moved
over the next adjoining area with an appropriate overlap and the process
repeated.
d. All areas where soap bubbles appear shall be marked, repaired and then
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Aldahham, HDPE Geomembrane Installation and Testing
 Work Method of Statement
for HDPE lining Installation and Testing

retested.
e. At locations where seams cannot be non-destructively tested, such as pipe
penetrations, alternate nondestructive spark testing by plant cupper wire
before extrusion welding done or equivalent should be substituted.
f. All seams that are vacuum tested shall be marked with the date tested, the
name of the technician performing the test and the results of the test and
make report diagram as shown below.

6. Double Fusion seams with an enclosed channel shall be air pressure tested by the
Geomembrane Installer in accordance with ASTM D 5820 and ASTM D 4437 and the
following equipment and procedures:
a. Equipment for testing double fusion seams shall be comprised of but not
limited to: an air pump equipped with a pressure gauge capable of generating
and sustaining a pressure of 210 Kpa (30 psi), mounted on a cushion to
protect the geomembrane; and a manometer equipped with a sharp hollow
needle ( as shown below ) or other approved pressure feed device.

Needle Gauge for Pressure test

b. The Testing activities shall be performed by the Geomembrane Installer. Both

ends of the seam to be tested shall be sealed and a needle or other approved
pressure feed device inserted into the tunnel created by the double wedge
fusion weld. The air pump shall be adjusted to a pressure of 210 Kpa (30 psi),
and the valve closed,. Allow 1 minute for the injected air to come to equilibrium
in the channel, and sustain pressure for 2 minutes. If pressure loss does not
exceed 28 Kpa (4 psi) after this three minute period the seam shall be
considered leak tight. Release pressure from the opposite end verifying
pressure drop on needle to ensure testing of the entire seam. The needle or
other approved pressure feed device shall be removed and the feed hole
sealed.
c. If loss of pressure exceeds 28 kPa (4 psig) during the testing period or pressure
does not stabilize, the faulty area shall be located, repaired and retested by the
Geomembrane Installer.

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Aldahham, HDPE Geomembrane Installation and Testing
 Work Method of Statement
for HDPE lining Installation and Testing

d. Results of the pressure testing shall be recorded on the liner at the seam tested
and on a pressure testing record.

7. Spark testing, technology was developed specifically for the quality control of exposed
geomembrane liners even where the damage is less than 1mm dia. the equipment will
generate an audio visual alarm to warn the operator that damage has been encountered.
It is employed directly after the installation of a liner. The system electronically verifies the
integrity of the entire surface including welds. This enables as to find all defects (e.g.
caused by installation, manipulation, transit, or following trades) down to invisible pinhole
sized damage. Can also be used in double lining systems where conductive-backed
geomembrane.

Spark Tester

C. Field Seam Destructive Testing (DT).

1. One destructive test sample per each 150 leaner meter (500 linear ft) seam length or
another predetermined length in accordance with GRI GM 14 shall be taken by the
Geomembrane Installer from a location specified by the Owner's Representative.
The Geomembrane Installer shall not be informed in advance of the sample location.
In order to obtain test results prior to completion of geomembrane installation,
samples shall be cut by the Geomembrane Installer as directed by the Owner's
Representative as seaming progresses.

2. All field samples shall be marked with their sample number and seam number. The
sample number, date, time, location, and seam number shall be recorded. The
Geomembrane Installer shall repair all holes in the geomembrane resulting from
obtaining the seam samples. All patches shall be vacuum box tested or spark tested.
If a patch cannot be permanently installed over the test location the same day of
sample collection, a temporary patch shall be tack welded or hot air welded over the
opening until a permanent patch can be affixed.

3. The destructive sample size shall be 300 mm (12 in) wide by 1 m (36 in) long with the
seam centered lengthwise. The sample shall be cut into three equal sections and
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Aldahham, HDPE Geomembrane Installation and Testing
 Work Method of Statement
for HDPE lining Installation and Testing

distributed as follows: one section given to the Owner's Representative as an archive

sample; one section given to the Owner's Representative for laboratory testing as
specified in paragraph, and one section retained by the Geomembrane Installer for
field testing as specified in paragraph.

4. For field testing, the Geomembrane Installer shall cut 10 identical 25 mm (1 in) wide
and 150mm length by coupon cutter as below ,replicate specimens from his sample.
The Geomembrane Installer shall test five specimens for seam shear strength and
five for peel strength. Peel tests will be performed on both inside and outside weld
tracks.

Coupon Cutter

5. If independent seam testing is required by the specifications it shall be conducted

in accordance with ASTM 5820 or ASTM D4437 or GRI GM 6.

6. Reports of the results of examinations and testing shall be prepared and

submitted to the Owner's Representative.

7. For field seams, if a laboratory test fails, that shall be considered as an indicator of the
possible inadequacy of the entire seamed length corresponding to the test sample.
Additional destructive test portions shall then be taken by the Geomembrane Installer
at locations indicated by the Engineer; typically 3 m (10 ft) on either side of the failed
sample and laboratory seem tests shall be performed. Passing tests shall be an
indicator of adequate seams. Failing tests shall be an indicator of non-adequate
seams and all seams represented by the destructive test location shall be repaired with
a cap-strip extrusion welded to all sides of the capped area. All cap-strip seams shall
be non-destructively vacuum box tested until adequacy of the seams is achieved. Cap
strip seams exceeding 50M in length (150 FT) shall be destructively tested. The test
will done by using the Tensiometer as shown above .

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Aldahham, HDPE Geomembrane Installation and Testing
 Work Method of Statement
for HDPE lining Installation and Testing

Geomembrane
Nominal 30mils 40 mils 50 mils 60 mils 80 mils 100 mils 120 mils
Thickness
Hot Wedge Seams (1)
shear strength(2), lb/in. 57 80 100 120 160 200 240
shear elongation at break(3) , % 50 50 50 50 50 50 50
peel strength (2), lb/in. 45 60 76 91 121 151 181
peel separation, % 25 25 25 25 25 25 25
(1)
Extrusion Fillet Seams
57 80 100 120 160 200 240
shear strength(2), lb/in.
50 50 50 50 50 50 50
shear elongation at break(3) , %
39 52 65 78 104 130 156
peel strength (2), lb/in. 25 25 25 25 25 25 25
peel separation, %

Table – Seam Strength and related Properties of Thermally Bonded Smooth and
Textured Linear High Density Polyethylene (HDPE) Geomembrane (English Units)

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Aldahham, HDPE Geomembrane Installation and Testing
 Work Method of Statement
for HDPE lining Installation and Testing

Liner Installation Project:

Daily Summary

Date:
Panel Dimensions
Weather am: Sub grade
Panel
Roll Number Accep.
Reference
Initials L W A
(m) (m) (m2)

Weather pm:

Hrs.
Lining Foreman:
Lining Technicians:
Hrs. Hrs.
1 9
2 10
3 11
4 12
5 13
6 14
7 15
8 16

Area Installed m2
Today:
Running Total Area m2
Deployed:
Length of Fusion Weld m2
Today:
Length of Extrusion Weld m2
Today:
Lab Destructive Sample Sent: No.
D.S. Reference From Seam
Reference

Details /Extra Work: Repair Report

Seam Panel Repair N.D.T Details
Reference Reference Technician Pass(intls)

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Aldahham, HDPE Geomembrane Installation and Testing
 Work Method of Statement
for HDPE lining Installation and Testing

Welding/Seam Log

Project Name : Material :

Location: Sheet Thickness:
Site Manager : Smooth: _______ Textured:____

Seam Number Time of Weld Date of Weld Type of Weld Length of Seam

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Aldahham, HDPE Geomembrane Installation and Testing
 Work Method of Statement
for HDPE lining Installation and Testing

Non-Destructive Test / Repair Log

Project Name : Material :
Location: Sheet Thickness:
Site Manager : Smooth: _______ Textured:_____

Seam Test Type Air Pressure test Test Result

Test Date Repair Locations
No. (A or V) Psi Start Psi Finish (S or F)

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Aldahham, HDPE Geomembrane Installation and Testing