Infrastructure method of Construction

1. Introduction
This document illustrates the method of construction for
Pk#100 under the contract of Mivida.

2.Purpose

This Document shows the main sequence of work and will

be use as a guideline for coordinating different work
trades

3. Scope Statement

Supply, installation, testing, commissioning and

guarantee with tie in to main network
A. Sewage Network
Network length= 983 m
Manholes no.= 35 (Precast/Cast in place)
Slow down chamber no. = 2 (Precast/Cast in place)
Granular bedding under pipes
House connection = 22 connections
Cutting and Restore into existing asphalt roads at Tie in
connections only
B. Domestic water Network
Network length= 1116 m
Valve chamber no.= 2 (Precast/Cast in place)
Water house connection = 20 for buildings and 2 connections for
guard room
Water meter chamber no. = 1 (Precast/Cast in place)
C. Irrigation Network
Network length= 1100 m
Concrete bedding under pipes
Gate Valve no.= 9
Note: Install 22 sleeves pipes crossing with tree center, this work
doesnt include excavation, backfilling and testing

D. Storm water Network

Network length= 1155 m (1095 m without branches)

 Granular bedding under pipes

Catch in basin no.= 20 (Precast/Cast in place)
Manholes no.= 2 (Precast/Cast in place)
Soak away no. = 3 (Precast)
E. Fire Fighting Network
Network length= 1294 m
Granular bedding under pipes
Gate Valve no.= 3 (Direct buried)
Fire hydrant no.= 17
F. Natural Gas Network
Demolishing existing connection
Network length= 1272 m (1112 m without branches)
Granular bedding under pipes
G. Tele-Communication System
Network length= 2085 m
Manholes no.= 2 (Precast/Cast in place)
Hand holes (GRP) no.= 32 (Precast/Cast in place)
H. Electric Network
Main excavation length= 1100 m
Direct buried cables= 11568 m
Laid in Trench cables= 25m
Transformer no. = 5 Transformer (In dwg 6 Trans. with 40 DP)
RMU = 5
I. Roads Network
Excavation = 10490 m3
Excavation for 40 distribution panels foundation = 20 m3
Precast Curbstones installation= 3490 m
Interlocking = 18535 m2

4. Sequence of work

3rd Phase

4th

Phase

2nd

Phase

1st Phase
4-1 Illustrative layout

4-2. WORK INSTALLATION

Precast concrete sewer and storm manholes and
pipe lines:

a) Excavate manholes and trench pipes lines and manholes in

accordance with approved shop drawings
b) Concreting blinding concrete in accordance to the approved shop
drawings
c) Install the precast concrete base of manholes in accordance to the
approved shop, drawings and the manufacturer recommendation
d) lay150 mm sand layer, compact, check compaction Granular
bedding layer for pipe lines accordance to the shop drawings.
e) lay piping shall be carried out in accordance with manufacturers
recommendations, as the following:
The bottom of the trench shall be trimmed ready to receive
the pipes Sand bags shall be driven into the bottoms of the
trenches at intervals not exceeding 3 meters.
lay the pipes and to be rested truly in the invert of the pipe
Install Two flexible joints shall be formed. The first joints
shall be as close as practicable to the structure and second
shall be at the other end of the first pipe. This first pipe
length shall not be more than 600 mm for pipes up to and
including 150 mm diameter and not more than 900 mm for
larger diameters up to 500 mm.
All pipes, fillings and other materials shall be carefully
lowered into the trench.
Precaution shall be taken to prevent foreign material from
entering the pipe while it is being placed
If the pipe cannot be placed into the trench without getting
earth into it, a heavy, tightly woven canvas bag of suitable
size shall be placed over each end and left there until the
connection is to be made to the adjacent pipe or fittings.
During laying operations, no debris, tools, clothing, or other
materials shall be placed in the pipe
Socket and spigot pipes shall be laid with the socket
pointing against flow direction.
The full length of each section of pipes and fittings shall rest
solidly on the pipe bed with recesses excavated to
accommodate bells, joints, and couplings, anchors.

f)
g)
h)
i)
j)

Supports shall be provided where necessary and where

indicated on the Contract Drawings.
Open ends of pipes at the end of day's work shall be closed
temporarily with wood blocks or bulkheads.
Pipes shall not be laid when the conditions of trench or
weather are unsuitable
The cutting of pipes for inserting valves, fittings or closure
pieces shall be done in a neat and workmanlike manner
'without damage to the pipes or lining and so as to leave a
smooth end at right angles to the longitudinal axis of the
pipes.
When machine cutting is not available for cutting metal
pipe 500 mm in dimeter or larger, the electric-are cutting
method is permitted.
Check installed pipe line size, type, level, direction and alignment
Back fill pipe line up to middle high of pipe with sand blanket
Grouting and concreting encasement the flexible short pieces
connected with manhole.
Grouting and concreting encasement the flexible short pieces
connected with manhole
TESTING GRAVITY DRAINS (Water testing of pipelines) in
accordance to Project specification the following:
All sections of installation shall be checked to ensure they
are free from obstruction debris before testing.
provide dean water, assistance and apparatus for testing
and inspection as required.
Temporarily seal low ends of drains and connections.
Fill system with water to produce 1.5 m head in a standpipe
at high end and not more than 4.0 m head at low end.
Allow pipeline to stand for 2 hours for absorption.
Measure loss at water by noting the quantity of water
needed to maintain the test head for 30 minutes.
Loss of water for drains not to be more than 1 liter per hour
per millimeter diameter per linear meter run. This may be
expressed as follows:
100 mm dia. Pipe

0.05 liters per meter run

150 mm dia. pipe

run

0.08 liters per meter

225 mm dia. pipe

run

0.12 liters per meter

300mm dia. pipe

run

0.15 liters per meter

k) Install the precast concrete risers in wall of manholes in

accordance to the approved shop drawings and the manufacturer
recommendation as the followings steps:
Clean the contact surface of precast base and contact
surface of precast riser.
Install the preformed approved sealant in location as per
manufacturer recommendation and shop drawings with
overlap 200mm at sealants joints.
Install precast wall riser vertically to the base with care not
to damage the sealant.
Repeat the above three points with installation precast riser
to precast riser up to the bottom level of manhole reducer
cover slab.
Install manhole lop reducer cover with cover opening over
out let sewer.
l) Complete the lining compound for interior and exterior surface
system for manhole base and internal and external wall.
m) Lay 30 cm sand blanket above the crown pipes accordance to the
approved shop drawings in layer and tamped by hand.
n) Concrete encasement shall be in accordance with cast in place
method statement and shop drawing for the following cases:
Depth of cover is less than 1200mm under roads
Under street lighting poles
Where water line crossing above sewer line and vertical
distance less than 300mm the sewer pipe shall be encased
for distance at least 1.0 m on each side.
o) Used suitable back filling materials for backfilling and compact in
300 mm layers the pipe line and around manholes up to ground
level in accordance to shop drawing.
p) Lay Pipeline marker tape 300 mm wide and 100 microns thick in
700 mm above the top level pipes during backfilling.
q) Cast concrete benching with slop as per the approved shop
drawing.
r) Test all manholes for water tightness not less than 4 weeks after
backfilling and before practical completion shall be as follows.
Temporarily seal all pipes entering chamber. To permit
draining of test water, seal outlet pipe where it enters the
next downstream chamber.
Fill chamber with clean water to a level of 1.5 m above
crown of outlet pipe or top of chamber if less than 1.5 m
deep.
Allow up to 8 hours for initial absorption and top up to test
level before commencing test.

 Water level must be maintained within 60 mm of original

level for 30 minutes without adding further water.
If permitted loss is exceeded, retest after a minimum period
of two weeks if permitted loss is exceeded at retest, remedy
defect before recommencing test sequence.
s) Install the covers and frames strictly in accordance with the
Manufactures instructions and recommendations and to the
details shown on Drawings and schedules, do not subject covers
gratings and frames to any loads until such times the bedding
haunching materials have adequately cured, set cover level with
surrounding finishes and square with joints surrounding finishes.

t) Before handing over part of pipeline, pass through if rubber disc plunger
or swab and in the case of jointed pipelines, simultaneously flush the
line with clean water.
u) Both ends then be closed by temporary plugs or bulkheads to prevent
entry of dirty or foreign matter.

Sewer inspection chamber and pipe lines

installation
a) Same as above points (a) and (b) of Precast concrete sewer manholes
and pipe lines installation.
b) Install the precast concrete gully in accordance to the approved shop
drawings and the manufacturer recommendation or caste in place the
base and wall of gully in accordance to cast in place concrete method
statement.
c) Same as above points from (d) to (u) of precast concrete sewer

manholes and pipe lines installation except paints (K) to be

cancelled.

Storm catch basin and pipe lines installation

a) Same as above points (a) and (b) of Precast concrete sewer
manholes and pipe lines installation.
b) Install the precast concrete gully in accordance to the approved
shop drawings and the manufacturer recommendation or caste in
place the base and wall of gully in accordance to cast in place
concrete method statement.
c) Same as above points from (d) to (u) of precast concrete sewer
manholes and pipe lines installation except points (I) and (K) to
be cancelled.

 SUB-BASE AND ROAD-BASE

A. CONSTRUCTION METHOD
1. Placing of Lower Subbase.
2. Placing of Upper Subbase.
3. Placing of Road Base and Wet Mix Macadam.

1. Placing of Subbase
a) Prior to placing any Lower Subbase material, the
underlying subgrade shall be shaped and compacted
in accordance to the specifications.
b) The material shall be placed over the full width of the
formation to the required thickness as shown in the
drawings in one layer or more, each layer not
exceeding 200mm compacted thickness.
c) Each layer of Lower Subbase shall be process as
necessary to bring its moisture content to a uniform
level throughout the material suitable for compaction.
d) The Lower Subbase shall be compacted using suitable
compaction equipment approved by the Engineer to
not less than 95% of the maximum dry density
determined in the B.S. 1377 Compaction Test (4.5 km
rammer method).
e) The top of Lower Subbase shall have the required
thickness, shape, super elevation, levels and grades
as required in the drawings and shall be within the
tolerances as specified in the specifications.
f) In the course of the construction, the level shall be
checked using control/dipping pegs, set out at regular
interval along both sides of the pavement.

2. Place of Upper Subbase

a) Prior to placing any Upper Subbase material, the
underlying subgrade or subbase shall be shaped and
compacted in accordance to the specifications.
b) The crushed aggregate from approved sources shall
be placed over the full width and to the required
thickness as shown in the drawings in one layer or
more, each layer not exceeding 200mmcompacted
thickness.
c) Each layer of Upper Subbase shall be process as
necessary to bring its moisture content to a uniform
level throughout the material suitable for

compaction. The correct moisture content of the

material shall be maintained by the sprinkling water
with a water truck.
d) The Upper Subbase shall be compacted using
suitable compaction equipment approved by the
Engineer to not less than 95% of the maximum dry
density determined in the B.S. 1377 Compaction Test
(4.5 km rammer method).
e) The motor grader shall be taken care in maintaining
uniform gradation of the materials and prevent its
separation into coarse and fine parts.
f) The top of Upper Subbase shall have the required
thickness, shape, super elevation, levels and grades
as required in the drawings and shall be within the
tolerances as specified in the specifications.
g) In the course of the construction, the level shall be
checked using control/dipping pegs, set out at regular
interval along both sides of the pavement. Joint
survey works on the existing road profile level shall
be carried out to establish the original profile of the
location being overlaid.

3. Placing of Road Base

a) The material shall be laid using an approved machineries
and compacted in layers in accordance with
specification. Any areas of compacted material having a
loose surface deficient in fines due to segregation or
otherwise shall be made good by being removed and
replaced with properly graded material.
b) Preparation of Road base follow previous layer procedure.
c) Prior to laying, the string line for the grade line sensor
shall be set out by the survey team at regular intervals
along the sides of the carriageway and shall be set to the
required levels.
d) After the string line level is jointly surveyed, the laying
operations may commence. Prior laying, foreman shall
ensure that all grade line and slope sensors are set and
working properly.

Construction of Electrical Network

Installation of an underground power cable generally

involves the following sequence of events:
1) ROW clearing, 2) trenching/blasting, 3) laying and/or
welding pipe, 4) duct bank and vault installation, 5)
backfilling, 6) cable installation.
Many of these activities are conducted simultaneously so as to
minimize the interference with ongoing site work.

1) Right-Of-Way Construction Zone

Underground construction begins by staking the ROW
boundaries and marking sensitive resources. Existing
underground utilities are identified and marked prior to the
start of construction.
Construction areas need to be wide and level enough to
support the movement of backhoes, dump trucks, concrete
trucks, and other necessary construction equipment and
materials.
2) Trenching Construction
A backhoe is used to dig the trench; the excavation starts with
the removal of the top soil in unpaved areas. Large trucks haul
away excavated subsoil materials to approved off-site location
for disposal, or if appropriate, re-use. In accordance with OSHA
requirements, trenches of a certain depth may require
additional shoring. Trench size will vary depending on the
cable type and the lines voltage. In many instances,
groundwater will be encountered during the trenching,
groundwater may be pumped from the excavation to a
suitable upland area or pumped directly into a tanker truck for
transport to a suitable location for release.
3) Conduit Assembly for XLPE Construction
Underground XLPE cable systems can be direct-buried or
encased in concrete duct banks. For duct bank installation, the
trench is first excavated a couple hundred feet. Then the duct
bank is assembled using polyvinyl chloride (PVC) conduit and
spacers.
4) Cable Installation

Cable pulling and splicing can occur any time after the duct
banks and vaults are completed. Prior to installation of the
cable, the conduit is tested and cleaned by pulling a mandrel
and swab through each of the ducts. A typical setup is to lace
the reel of cable at the transition structure or at one of the
vaults and the winch truck at the next vault. The cable is then
pulled from the transition structure to the nearest vault.
Direction of pull between vaults is based on the direction that
results in the lowest pulling and sidewall tensions. Cable
lengths are spliced within the vaults.
5) Backfilling
A special backfill material is used instead of soil in the trench
around the cables to ensure sufficient heat transfer to the
surrounding soils and groundwater.

TRANSFORMERS
A. GENERAL:
1. Transformers shall have all-copper windings.
2. Electric panels shall not be mounted inside transformer
enclosures.
3. All transformers are to be new.
4. Transformers shall be Radially fed only, with an upstream SF-6
switch to de-energize the design shall only be utilized for
simplifying the wiring congestion within the High Voltage
compartment. When the transformer is internally wired as a
Radial feed transformer,
5. All conduits shall enter & exit transformer from beneath the pad.
B. TESTING

1st Sewage network

2nd Storm drainage

network

3rd Domestic water network

4th Fire network

5th Irrigation network

6t

Natural gas network

7th Medium voltage network

8th Low voltage network