Table of Contents
1. SCOPE...........................................................................................................................
2. REFERENCE ..................................................................................................................
3. DEFINITION .................................................................................................................
4. RESPONSIBLITIES ........................................................................................................
5. EXECUTION ORGANIZATION ........................................................................................
6. WORK PROCEDURE.....................................................................................................
7. QUALITY REQUIREMENT ...........................................................................................
8. SUBMITTALS..............................................................................................................
9. APPENDIX..................................................................................................................
WORK METHOD STATEMENT
(Construction of Maintenance Road-KGI)
Page 2 of 16
1. SCOPE
This is Working Method Statement shall be implemented to the SITE
PREPARATION work
of Wasit Gas Plant for the SULFUR RAILCAR LOADING FACILITIES
PROJECT. The SITE
PREPARATION work shall be the Earthwork consisting but not limit to
Cleaning & Grubbing,
Embankment fill, Cutting, Compacting and Disposal for the preparation
of platform support
the Road/facility structure.
2. REFERENCE
The selection of material and equipment, and the construction,
maintenance shall be
referenced and comply with the latest edition of the codes and
standards listed below,
unless otherwise noted.
2.1. Saudi Aramco Engineering Standards
(a) SAES-A-111 Borrow Pit Requirements
(b) SAES-A-114 Excavation and Backfill
(c) SAES-Q-006 Asphalt and Sulfur Extended Asphalt Concrete
Paving
2.2. Saudi Aramco General Instructions
(a) GI-0002.100 Work Permit System
2.3. Saudi Aramco Manuals
(a) Saudi Aramco Construction Safety Manual
(b) Saudi Aramco Blasting Services Manual
2.4. Quality requirement Schedule Q
2.5. Industry Codes and Standards
(a) ASTM C136 Sieve Analysis of Fine and Coarse Aggregates
(b) ASTM D422 Particle-Size Analysis of Soils
(c) ASTM D1140 Standard Test Methods for Amount of Material in
Soils Finer than the
No. 200 (75-um) Sieve
(d) ASTM D1556 Standard Test Method for Density and Unit Weight
of Soil in Place by
the Sand-Cone Method
(e) ASTM D1557 Laboratory Compaction Characteristics of Soil
Using Modified Effort
56,000 ft-lbf/ft (2700 KN- M/M)
(f) ASTM D2487 Classification of Soils for Engineering Purposes
(g) ASTM D4253 Maximum Index Density and Unit Weight of
Soils Using a Vibratory
Table
(h) ASTM D4254 Minimum Index Density and Unit Weight of
Soils and Calculation of
Relative Density
(i) ASTM D4318 Liquid Limit, Plastic Limit and Plasticity Index of
Soils
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2.6. Process Industry Practices
(a) PIP CVS02100 Site Preparation, Excavation, and Backfill
Specification
3. DEFINITION
3.1. Brackish Water
Brackish Water with Total Dissolved Solids of 10,000 ppm or more
3.2. Clean Sand
Soil meeting the following gradation containing less than 3% weight of
organic material or
clay:
Sieve Size
Percent Passing
in (6.25mm)
100
No. 10 (2.00 mm)
90-100
No. 200 (0.075mm)
10 or Less
3.3. Company Representative
Saudi Aramco's authorized representative with overall authority and
responsibility for the
project.
3.4. Contract or Contract Documents
Any and all documents, including design drawings, which Saudi Aramco
has transmitted or
otherwise communicated, either by incorporation or by reference,
and made part of the
legal contract or purchase order agreement between Saudi Aramco and
the Contractor.
3.5. Contractor
The party responsible for performing excavation and backfill,
including work executed
through the use of sub-contractors
3.6. Dune Sand
Dune Sand is wind-deposited sand consisting of relatively single-sized
particles generally
passing the No. 16 sieve (1.18 mm) and usually containing less
than 10% soil particles
passing the No. 200 sieve (0.074 mm).
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3.7. Fill Material
Fill Material will be gravel, sand or marl as specified by
6.2.1 of SAES-A-114 and
recommended by Geotechnical Investigation Report provided by the
Company.
3.8. Hard Rock
Hard Rock see Rock Excavation, section 7.5of SAES-A-114
3.9. Marl
Marl is a wide variety of calcareous soil materials found in Saudi Arabia
which may vary
from clay to gravel sizes and often include cobble and boulder sized
pieces.
3.10. Rocks
Rocks have various hardness and engineering properties. "Rock"
may refer to anything
from boulder-size individual pieces to hard,
intact bedrock. See section 7.5 for
classification of rock by excavation method.
3.11. SABKHA
SABKHA is a saline (generally coastal) deposit
generally consisting of saturated,
loose silty sand and possibly clay.
3.12. Select Fill Material
Select Fill Material see section 6.2.2 of SAES-A-114
3.13. Soft Rock
Soft Rock see Normal Excavation, section 7.5 of SAES-A-114
4. RESPONSIBLITIES
4.1. Construction Manager [CM]
The Construction Manager will be in charge of construction
activities assisted by Project
Engineers, Site engineers, Assn. Engineers, Junior Engineers and
Supervisors, who will
execute and supervise each and every work. The basic functions
of the Construction
Manager and his team of engineers and support staff include:
- Supporting the Site Manager in Project Management activities
- Construction Management
- Coordination and supervision of Subcontractors
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- Entire Construction Activities assigned to them.
- Implementation of environmental protection measures
4.2. Quality Control Manager [QCM]
Establish, maintain and implement the approved
Project Quality Plan and Overall
responsible in quality for all construction activities including materials
receiving as to the
applicable codes and standards and control the quality control
personnels inspection
activities to ensure compliance with the quality requirement.
4.3. Quality Control Supervisor [QCS]-Railway Part
Implement the Project Quality Plan to the project and Direct responsible
in quality and
establish the ITP, manage the inspection of the work and review the activity of
the Quality
Control Inspector. All field quality control document and inspection
records as to the
requirement of Schedule Q shall be prepared, maintained and submit to
QCM.
4.4. Quality Control Inspector [QCI]-Railway Part
Responsible in quality control of the work providing that physical inspection in
routine for
every stage of the activities as to the codes and standards and procedures and
deliver the
technical advice to the construction team to keeping the quality
requirement. All the
inspection activity shall record as per the designated checklist submit to QCS
and raise the
RFI as upon satisfaction of the inspection result guided by QCS/QCM
4.5. Safety Officer
Ensure all work permits are available prior to commencement of any work as
per
Saudi Aramco Work Permit System. Check personnels compliance with
safety
requirements, such as wearing Personnel Protection Equipment (PPE). Check
work
areas for any unsafe conditions. Liaise with Field Supervisors and
Foremen that
work is carried out in accordance with Project Safety Plan / Procedure.
4.6. Field Control Manager [FCM]
Ensure to Manage the Project Communication and responsible for Clients
review and
approval of Drawings, Data and establish the Technical resolution to the
problem if
occurred during the work.
4.7. Field Engineering Manager [FEM]
Ensure to provide technical support to construction operation section and
provide IFC
drawings base on geotechnical investigation report (Geotechnical File #
2013/84), material
specifications, standards and technical specifications.
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5. EXECUTION ORGANIZATION
5.1. Equipment and Manpower
The capacity of the below mentioned equipment and manpower
shall be mobilized in
accordance with site conditions and requirements. Below listed
equipment will be the
principal.
5.1.1. H/Equipment Plan
Description Capacity Unit
Qty
Excavator 0.8~1.3m3 Nos.
5
Dump Truck 24m3 Nos.
50
Motor Grader 3.6M Nos.
8
Wheel Loader 2.9m3 Nos.
3
Vibratory Roller 10ton Nos.
10
Bull Dozer 36ton Nos.
1
Plate Compactor Industrial Nos.
1
Water Truck 5000L Nos.
3
5.1.2. Manpower Plan
Description Qty
Responsible
Overall responsible in construction
of the Site
Construction Manager 1
Preparation Work
Site Engineer 2 Direct Responsible for Site
preparation Work
Site Supervisor 4 Supervising the Work
Surveyor 2 In charge of Surveying Work
Surveyor helper 4 Assist Surveyor
Overall responsible in Safety for
the Site
HSE Supervisor 2
Preparation Work
Direct responsible in Safety for the
Site
HSE Officer 4
Preparation Work
Flagman 4 Traffic Control
Common Labor 20 General Crafts of Work
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5.2. Work Flow Chart
WORK PERMIT RECEIVED
SURVEY WORK
BORROW-PIT
DEVELOPMENT
-TBM Installation
-Setting Out
-Extraction & Stockpiling
-Sampling & Testing by TPTL
CLEANING & GRUBBING
MATERIAL APPROVED
-Remove Unsuitable Materials
-Remove Top Soil & Stripping
-Remove Trees
EXCAVATION
EMBANKMENT
-Cuttings
-Foundation Treatment
-Subgrade Preparation
-Placement & Compaction
-Replacement[If required]
-Final Grading
COMPLETION
-Final Inspection
of
FILL/SUBGRADE
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6. WORK PROCEDURE
6.1. Borrow-pit Management
The Borrow-pit source for the project shall be the location
designated by the SAPMT
and/or Contractor shall be proposed the both locations where will be
within approx. 15km
away along with SAR line CTW 110 under construction as shown in
Appendix 10.1.
6.1.1. Development of Borrow-pit
The Development of Borrow-pit shall be guided by the SAES-A-111.
The material can be obtained Fill/Select Fill material as it consist
of gravel, sand and/or
marl by excavation and managing the stockpiles to be ready to
delivering the site when the
material is verified as per the utilization requirement in accordance with
SAES-A-114.
6.1.2. Stockpiling
The material extracted from the borrow-pit shall be maintained by
stockpiling separately
as to the soil classification in use.
Stockpiling of the materials shall be kept in height of 5m in maximum
and provide a berm
with a width of 1m at 3m height.
The side slope of stockpile shall maintain as below;
- Cohesiveness Soil : 1V : 2H
- Cohesive-less Soil : 1V : 3H
6.1.3. Verification of Materials
The material extract from the Borrow-pit shall be classified and
verified as per the
utilization purpose and stockpiled separately in temporary lay-down area
to be provided
adjacent to the Borrow-pit.
The classification of the material shall be referenced to para.3.0
Definition.
6.1.4. Inspection & Testing Plan
The inspection and testing of stocked material shall be carried out
in accordance with
Schedule Q which will be tested and verified by TPTL under witnessed
by the PID as per
the procedure designated.
The frequency of the testing the material to verification will be as below;
Test Description Test Standard Applicable
Material Test frequency
Gradation ASTM C136 All type of
materials
Passing No.200 Sieve ASTM D1140
Liquid Limit & Plasticity All type of
materials 2 tests per
ASTM D4318
Index except Fill
2,500
Modified Proctor Test ASTM D1557
ASTM
Max. & Min, Density Test Clean/Dune sand
only
4253/4254
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6.2. Site Preparation Works
6.2.1. SURVEY AND SETTING OUT
The surveying coordinates system, horizontal and vertical datum, Datum
Transformation
to the work shall be in accordance with SAES-A-100.
The Survey Control Point endorsed by the Company shall be the Temporary
Bench Mark
(TBM) which will be confirmed by Third Party Survey Service Provider and
confirmation
report submit to the Company for approval in prior to all Setting out of the Site
Preparation
work may commence.
The applicable tolerances of Earthwork shall be;
- Location of Embankment:
Deviated from Design Line: +150mm/-50mm
Distance from Centerline to Subgrade Outer Edge:-0mm/+150mm
- Elevation in Grade:
Earthwork [Fill]: 50mm
Formation Level[Subgrade]: +0mm/-25mm
6.2.2. Demolition
Areas that have existing abandoned structure such as foundation/
pedestals, walls and
other similar structure that will obstruct the development works of the
project must be
excavated and removed/demolished from the site, including the scraping
of existing
asphalt pavement up to the base coarse level. The unsuitable material should
be disposed
at designated area(Please see section 9.1 Borrow pit and Disposal area)
6.2.3. Cleaning & Grubbing
Clearing and grubbing shall consist of the removal and disposal of all trees,
stumps, roots,
logs, shrubs, grass, weeds, fallen timber and other surface litter,
wherever they occur
within the right-of-way and within such other areas as directed and staked out
by the PMT.
- Clearing and Grubbing inclusive of backfilling holes and trenches caused
by removal
of stumps
- Removal of trees subject to consent of PMT
- Removal of overhanging branches of girth
- Removal of Structures and obstruction
6.2.4. Excavation and Subgrade Preparation [Cutting to receive Pavement
or Structure]
(a) Areas to receive fill, foundations, pavement or areas to be used to
support structural
loads shall be free of roots, trash and other unsuitable material.
Stripping shall
consist of the excavation, removal, and satisfactory disposal of all
topsoil and soil
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containing organic material or excessive. Such material shall not be
used as fill
material under any circumstances.
(b) Excavation shall be made to the lines, grades and cross sections as to
the IFC drawing.
(c) Side slope of excavation shall be cut true and straight and shall be
graded to the cross
section shown in IFC drawing.
(d) Construction of new slope shall be accomplished by compacting
horizontal fill layers
at least 1 roller width beyond the design edge of the slope and then
trimming back to
achieve the final slope dimensions.
(e) The surface of existing ground after excavated and stripped shall be
the Subgrade
and shall be treated as per the para.4.3 & 5, SAES-Q-006.
6.3. Embankment
The embankment usually refers to an earthen structure that is used to raise up
above the
elevation of the surrounding area where to be received Road Structure,
Railway or
Structure Foundation.
(a) Embankment Foundation.
All debris, unsuitable material and vegetable matter shall be
removed from the
surface upon which the embankment is to be placed and the cleared
surface shall be
completely broken up by plugging, scarifying or stepping to a
minimum depth of
30(thirty)cm.
(b) Fill material shall be placed in lifts not exceeding 200 mm (8 in) in loose
depth. Fill
materials shall be placed in lifts not exceeding 100 mm (4 in) in loose
depth for hand-
operated compaction. Other lift thicknesses may be approved by
the appropriate
Saudi Aramco PID based on the proposal of Field Trial using
the intended
compaction equipment.
(c) For foundation for asphalt and concrete pavement subgrades, fill shall
be compacted
to 85% relative density for cohesion-less soils or 95% of the
maximum density as
determined by ASTM D1557 for cohesive materials.
(d) The moisture content of the material being compacted shall be
within 3%, plus or
minus, of the optimum moisture content as determined by ASTM D1557.
However,
for cohesion-less free draining soils when ASTM D4253/ASTM
D4254 is the
appropriate test procedures, there is no applicable optimum moisture
content.
(e) If clean sand or dune sand is used for fill, surface protection will be
required. A cap
layer of compacted cohesive material 150 to 300 mm (6 to 12 in) in
thickness will
generally be sufficient. Capping material shall have a maximum
size of one-half lift
thickness or 75 mm (3 in), whichever is less, and shall have between 11
-35% passing
the No. 200 sieve. The capping material shall have a maximum liquid
limit of 35 and a
maximum plasticity index of 12, per ASTM D4318.
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Page 12 of 16
7. QUALITY REQUIREMENT
The Quality work control shall be implemented
as per the approved Quality
Documents(Quality Plan & Inspection & Test Plans) of Schedule Q .
8. SUBMITTALS
The following submittals shall be transmitted
to the Saudi Aramco Company
Representative
8.1. Reports including all laboratory and field test logs and comments,
Field
test reports shall include density and moisture content test logs
indicating
location by coordinates and elevation. Reports shall be submitted on
the
following:
8.1.1. Bi-weekly.
8.1.2. At earthwork completion: A complete record of all test logs
and comments for permanent project records.
8.2. Borrow (Fill) Materials and Water Sources and test results of all
borrow
materials and compaction water used for fill prior to beginning
fill operations as
according to SAES-A-114.
8.3. Excavation Plan, including a Pre-Excavation checklist, as per the
Saudi
Aramco Safety Management Guide 06-002-2008. All excavations,
including shoring and
sheeting materials and systems, shall meet the minimum
requirements established by
the Saudi Aramco Safety Management Guide 06-002-2008. If
an Excavation Plan is
required and shoring is used, the Plan is to:
(a) Describe the materials and shoring system to be used.
(b) Indicate whether or not any components will remain after filling or
backfilling.
(c) Provide plans, sketches and/or detail along with calculations.
(d) Indicate the sequence and method of shoring installation and
removal.
8.4. Dewatering. If dewatering of an excavation is required, the
Contractor
shall submit proposed methods and details
to the Saudi Aramco Company
Representative for review, before beginning dewatering and
excavation.
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9. APPENDIX
9.1Location Map of Borrow pit & Disposal
Borrow-pit for Marl Material
Borrow-pit for Sand -Pit
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Disposal Area
9.2 ITP FORMAT
- Earthwork-Site Preparation, Excavation and Backfill during
Construction:
ITP No.: SATIP-A-114-01 (see APPENDIX 9.2.1)
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9.2.1 SATIP-A-114-01
SAUDI ARAMCO ID/PID FORM REV 1 - 010109
Rev 3 COS 06/30/2008
SAUDI ARAMCO TYPICAL INSPECTION PLAN
SATIP No. APPROVED DATE DISCIPLINE:
Earthwork - Site Preparation, Excavation and Backfill During
SATIP-A-114-
01 20-Feb-10 CIVIL
Construction.
PROJECT TITLE:
WBS/BI/JO/NO. CONTRACTOR/SUBCONTRACTOR
SULFUR RAILCAR LOADING FACILITIES
BI-10-01825 POSCO ENGINEERING & CONSTRUCTION Co.,LTD.
INSPECTION RESPONSIBILITY
ITEM PROJECT PHASE & QUALITY
QUALITY ASSIGNMENTS
TASK / ACTIVITY
REMARKS
NO. ACTIVITY CODE PROCEDURE
RECORD SAUDI
CNTRCTR
ARAMCO
1.0 DOCUMENT REVIEW
Contractor - "RH" of Documents and "H" for Material
Sampling and Testing.
Soil Sampling, Testing and Review of SAIC-A-
S.ARAMCO - "RH" of Documents and "H" for Material
1.1 SAIC-A-1001
RH/ H RH/ H
Test Reports 1001
Sampling and Testing for first 2 occurences and once
every 5 occurences thereafter on Mega Projects. "W"
for other occurences and for other Projects.
2.0 MATERIAL RECEIVING
S. ARAMCO - Witness delivery of fill, select fill and marl
Fill, Select Fill and Marl Cap Materials SAIC-A-
2.1 SAIC-A-1002
W S cap materials for the first 2 delivery days, and once
Receiving Inspection 1002
every 5 delivery days thereafter.
3.0 INSTALLATION
Soil Protection and Control, Drainage SAIC-A-
S. ARAMCO - Witness 2 occurences, and once every
3.1 SAIC-A-1003
W S
and De-watering Inspection 1003
5 occurrences thereafter.
Fill Placement and Compaction SAIC-A-
S. ARAMCO - Witness 2 occurences, and once every
3.2 SAIC-A-1004
W S
Inspection 1004
5 occurrences thereafter.
SAIC-A-
3.3 Compaction Testing SAIC-A-1005
W W
1005
SAIC-A-
3.4 Final Fill Inspection SAIC-A-1006
I W
1006
4.0 PRE-COMMISSIONING
4.1 Not Applicable
GENERAL NOTES
The first three incidents of each Inspection or testing activity listed require
100 % participation by Saudi Aramco Site Inspection Personnel. After this period,
Saudi Aramco Inspection may adjust
the levels of Saudi Aramco participation based upon the Contractors
performance.
2 Surveillance: QA/QC organization to monitor work in progress without notice
from Construction Organization
Witness: QA/QC organization shall be notified of the timing of Inspection or
test in advance. However, the inspection or test shall be performed as scheduled if
the QA/QC organization
representative is not present.
Hold: QA/QC organization shall be notified of the timing of inspection
or test in advance. Inspection or test shall not be carried out without the QA/QC
organization representative in
attendance.
5 If the Main Contractor delegates the assigned responsibility to the
Subcontractor, then the Main Contractor will have the same degree of responsibility
as assigned to Saudi Aramco.
LEGEND
H 100% Hold Point for QC Inspection or Test. R
Review of Documents
W Witness Inspection/Test RH
Review and Approval of Documents
S Surveillance I 100%
Contractor Inspection
