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1.

PURPOSE
The purpose of this Method Statement is to provide General Guidelines for
Cable laying & Cable Termination for the Project PE # 434 : Power, Control
& Signal Cables for The Scrap Pellet recovery project for Abu Dhabi
Polymer Company Ltd. (BOROUGE) at the Ruwais Industrial Area, Abu
Dhabi Emirate.
2. SCOPE
Scope of this Method Statement covers the following activities.

Material Handling

Procedure

Precautions

Testing

Inspections
3. REFERENCES
The Following documents & drawings are considered for reference
documents:

Project Specific Cable Route drawings. {please indicate specific


drawing references}

Project Specifications

Project Quality Plan (PQP)

Inspection & Test Plan(ITP)


4. DEFINITIONS
OWNER: Abu Dhabi Polymer Company ltd. BOROUGE
ENGINEER: {please indicate Consultant/Engineers name.}
CONTRACTOR: Al Husam General Contracting Est.
DAY:
A consecutive calendar day unless otherwise stated
MAY:
Is used where a provision is discretionary
PLANT:
Machinery, computer hardware and software, apparatus,
materials, articles and things of all kind to be provided under
the contract other than Contractors Equipment.
PROJECT:
Project PE #434 Scrap Pellet recovery project for Abu
Dhabi Polymer Company Ltd. (BOROUGE)
SE:
Site Engineer
SUP:
Supervisor
ITP:
Inspection & Test Plan
E&I:
Electrical & Instrument
QA/QC:
Quality Assurance and Control
IFC:
Issued for Construction
PPE:
Personal Protective Equipment
HSE:
Health Safety & Environment
5. MANPOWER & EQUIPMENT
5.1

MANPOWER

5.1.1 PROJECT MANAGER :


The Project Manager has the overall administrative responsibility for
the implementation of this method statement.
Coordinates the works with the Site Manager to ensure they are carried
out according to the planned program.

Conveys to the Site Manager the importance of adhering to all safety


measures and quality control in co-ordination with Safety Engineer and
QC Engineer and in line with the HSE Plan and Quality Plan.

5.1.2 Site Manager :

The Site Manager has the overall site responsibility for the
implementation of this method statement.
Ensures that approvals from all concerned authorities has already been
obtained before proceeding with trial pit excavation and made
available to his site team.
Ensures that the works are carried out according to the planned
program and that all the equipment required to execute the works shall
be available as per the project planning and are in good condition.
Coordinates with the Project Engineer / Site Engineer, Safety Engineer,
Quality Control Engineer and for the orderly, safe and proper execution
of the work.
Specific attention shall be given to all safety measures and quality
control in co-ordination with Safety Engineer and QC Engineer and in
line with the HSE Plan and Quality Plan.

5.1.3 Project Engineer / Site Engineer:


Ensures that all the works are to be carried out according to the
specifications and approved shop drawings.
Provides all necessary information and assigns the responsibilities to
his construction team.
Ensures and monitors the work progress of work in accordance with the
required program and report the same to the Project Manager.
Coordinates with the Safety Engineer to ensure that the works are
carried out in a safe working practice.
Coordinates with the QA/QC Engineer for the tests (if any) to be carried
out and initiates for the inspection for the work activities.
Ensures the implementation of any request that might be raised by the
Consultant.
Coordinates with the site foreman and plans the works in advance as
per the work sequence.
5.1.4 Surveyor:
Shall ensure that New Abu Dhabi Datum reference survey
points/markers are obtained and located at or near the work site.
Shall ensure that all coordinates values are in WGS 84-UTM, Zone 39N
Coordinate System.
Shall ensure that existing buried services are already located, identified
and exposed prior to excavation.
Shall supervise the checking of trench depth and grade (as may be
required) during excavation.
5.1.5 HSE Engineer/Officer:

Ensures the implementation of all Safety measures in accordance with


the HSE plan and ensures that everybody is fully aware of it for safe
work implementation.
Ensures all the implemented safety measures are adequate to maintain
the safe working environment on site.
Inspects all the site activities and trains the persons to prevent
incidents and avoid accidents and to properly report any incidents and
accidents to the Project Manager and Consultant.
Ensures that the site is maintained clean, tidy and free of obstacles
that could endanger safety.

5.1.6 QA/QC Engineer:


Ensures that all the required permits and clearance are already
obtained and still valid before starting the work.
Maintains inspection and test records complete for any future
reference.
5.1.7 Other Personnel requirement:

i.
ii.
iii.
iv.
v.

Technicians
Helpers
Banks men
Fork lift operator
Crane Operator

Whose responsibilities include


Follow Safety Rules & Regulations
Report any hazard in work place
Report any accident or near miss
Identify risks in workplace and associated hazards
The usage of issued PPE
Report any defects in machinery and equipment
Report any non-conformance identified at work site

5.2 Equipment / Tools


{Please add or delete equipment according to site requirement}
a) JCB Excavator
b) Hi-Up
c) 20 Ton Mobile Crane
d) Plate Compactor
e) Cable Rollers
f) HV Cable Joint Kit
g) Cable Trolley
h) Crimping Press
i) Cable Pulling Winches
j) Transportation vehicle
k) Portable Lights
l) Jointer Tool Box
m) Electrical Tool Box
n) H.V. Cable Saw
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o) AC High Voltage Test Kit / VLF Test Kit


p) Manual Excavation Tools
q) Removable Barricades
6. PROCEDURE
6.1 EXCAVATION & BACKFILLING
6.1.1PREPERATION & PRECONDITIONS
a) Permit to Work (PTW) if required shall be raised to the Owner/Engineer
for the excavation clearly mentioning the location of work, size of
excavation and levels.
b) Excavations area shall be surveyed and marked to the lines and levels
as shown on the drawings.
c) The area of excavation will be cordoned off using safety barricading to
stop trespassers.
d) Assign sufficient banks men, helpers and supervisors at the site prior to
start of excavation.
e) Required sign boards such as DEEP EXCAVATION MEN WORKING,
DANGER and warning boards will be placed to indicate the excavation
work.
f) Ensure the working area at any confined space is free from any
Hazardous Gas by proper Gas testing using the Gas testing instrument.
g) If there are structures adjacent to the work area, proper temporary
supports shall be provided to the adjacent structure prior to start
excavation.
h) Fences and minor structures of any character or upon within the limits
of the works and not necessary for the construction shall be removed
carefully and stored neatly for reinstating after the construction works.
i) If any Survey points, bench marks, boundary stones and markings
falling on the area shall be removed only with the OWNER / ENGINEER's
written consent and shall be stored and reinstated according to OWNER
/ ENGINEER's instructions.
j) Check the area of excavation to find out any underground facilities
other than listed in topographical survey by:
Using appropriate detective equipment, such as cable detector,
metal detector etc.
Check existing exposed excavation nearby area to find out
existing underground facilities.
Refer available As-built drawings from the Company, other
agencies, other contractors doing projects nearby areas and mark
in the area.
Take trial/ test pits to find out existing underground pipes,
structures.
Check the indication marks, signs, manholes nearby area and find
out the path of services.
6.2

EXCAVATION

6.2.1 Trial Pit and Excavation Procedures

a) Prior to star of any excavation, the area shall be checked for the
existing services/ utilities by obtaining the approvals with reference to
the relevant drawings.
b) The necessary excavation activities shall start only after getting the
notice intent from the Concerned Authorities who have services
/installation in the vicinity or plan to install their services in the general
area in the near future.
c) Excavation of the trial pits shall be done manually as per the size
indicated in the approved drawings up to the required length and level.
d) In open areas the excavation shall be carried out by using the
machineries, the exact location of each trench and pit being subjected
to the prior approvals.
e) Manual excavation will be carried out to expose the existing utilities, if
any, which has to be identified.
f) The trenches shall be kept dry during cable installation operation. The
contractor shall deal with the dispose of water so as to prevent any risk
to the cables and other materials.
g) The contractor shall provide suitable dewatering while performing the
works according to the scope of work.
h) The required control measures shall be developed and implemented
while performing the works and more importance will be given for
public safety and environmental issues.
i) While performing the work the trenches shall be straight, free from any
sharp objects/edges likely to injure the cable or accessories and filled
with soft sand and sieved sand to form smooth bedding before the
cables are laid.
j) The contractor shall take the necessary precautions to prevent damage
to the road or ground surface due to a slip or breaking away from the
side walls of the trench including the pedestrian safety as well.
k) The vehicle entry shall be restricted on the specified work area by prior
approval from the concerned agencies.
l) Where ever there is a crossover of the existing services/utilities, these
shall be protected with utmost care with the prior permission of
concerned authorities and approved methods.
m) In case of other projects in the same vicinity, the contractor shall
obtain the necessary approval from the Owner/Engineer & the Engineer
for the concerned project to clarify the scope of the works and
boundaries of the other project, according to the scope of the work.
n) Excavate the area by using only hand tools as per the markings and
levels with proper protection of sides
o) The bottom of the excavation shall be levelled and trimmed to receive
the permanent works.
p) Provide proper rigid barriers around excavations include provision of
ladders, emergency escape way, adequate side slopes or shoring and
shuttering, detours.
6.2.2 EXCAVATION ADJACENT TO UNDERGROUND SERVICES
a) Excavation near the existing electrical cables, instrumentation and
control cables, sewer line, gas lines and any other service line shall
take all necessary precautions to protect the services with proper
supports & covers.

b) All existing structures, foundations, pipes and cables, if any, which are
to be incorporated into the final work, shall be adequately protected
from damage.
c) All underground services located during excavation shall be mapped for
consideration during construction of the works.
d) If any underground service is noticed other than specified in the area
during excavation shall be brought in notice of the OWNER
e) Excavation shall not be carried out adjacent to or near existing building
foundations, without suitable shoring/sheet piling.
6.3
BACKFILLING
6.3.1General
a) Backfilling area shall be backfilled with approved material compacted
in layers by suitable equipment like plate compactors, vibratory roller
compactors, etc., until the specified density has been obtained to the
satisfaction of the OWNER/ ENGINEER.
b) Compacting shall be carried out with special care by means of
mechanical tampers of a type approved by OWNER/ENGINEER to avoid
damage to structures.
6.3.2BACKFILLING MATERIALS
a) Backfilling materials shall be free from stones or rocks larger than 50
mm, or other material which might prevent proper compaction or cause
the compacted fill or embankment to perform inadequately.
b) Backfilling materials shall be free from fossil content, clay, vegetation
and its roots, waste materials, Material containing gypsum or other
soluble salts greater than the allowable limits.
c) Following classified materials shall not be used for backfilling.
Organic material, logs stumps and perishable materials.
Material susceptible to spontaneous combustion.
Materials with undefined properties.
Materials having moisture content greater than the maximum
specified.
Building rubble and domestic and industrial wastes.
Soils and rock susceptible to deterioration/change of their
properties.
Clay, silt and other loose or soft soils not in accordance with
compaction criteria.
Dredged material.
Rock materials
6.3.3FILLING OF MATERIALS
a) Fill material shall be spread and compacted in 300 mm layers, with a
compacted layer thickness not exceeding 300 mm where mechanical
compactors like vibratory plate/drum compactors are used.
b) The thickness of fill material shall not exceed 150 mm where manual
compaction methods are adopted.
c) If the thickness of loose fill layers required to exceed 300 mm written
approval including methods of compaction shall be required from the
OWNER/ENGINEER.

d) If the surfaces receiving fill layers is smooth, then scarified to obtain a


good friction/key between the new fill layer and the sub grade.
e) Excavated materials may only be used for backfilling after obtaining
necessary permissions or approvals from the Owner/Engineer.
6.4
Formation of Cable Trench.
a) The formation of the trench shall be in accordance with Project
Drawings and Specifications.
b) The trench shall be excavated upto the required depth of 0.76 Mtr. from
the existing ground level
c) Dune sand bedding shall be done for a thickness of 150mm at the
bottom of the trench using TR tested and approved dune sand, prior to
the installation of cables.
d) Cables are laid over the dune sand bedding
e) Approved sand/backfill material is filled in the trench to the required
level as per approved drawing.
f) Sufficient Water is poured to match the required Moisture content
g) Cable protection tiles are laid above the dune sand filling
6.5

Final Backfilling.

a) Ensure the Concrete Cable Tiles are securely placed.


b) Selected sieved materials from the excavated soil shall be backfilled for
a thickness of 250mm above the cable protection tiles. Care shall be
taken to avoid stones and boulders mixing with the backfill material
c) Install Cable Warning Tape at a height of 250mm from top of the
concrete cable tiles
d) Backfill to the required level in similar way.
e) Ensure Proper Compaction of soil is done after every 150mm layer laid.
f) Reinstate the area as to its original situation.
7.0 CABLING
7.1 Material Handling
a) The Material RECEIVED FROM Client shall be stored in designated area
of the Store/storage facility.
b) Arrangements shall be made to protect the cable drums against effects
of weather and environment.
c) Material inspection will be carried out to ascertain that no damage has
occurred to the Cables.
d) In case of any damages common inspection and report will be issued.
e) Cable shall be tested on cable drums prior to removal and work site
with a 1000 V insulation tester (5KV for MV Cables).The values will be
noted for Core to Core and Armour.
f) After the test, the end of the cable shall be sealed to prevent the
ingress of moisture.
g) Store material requisition shall be made.
h) The material shall be transported in their original packing to location.
i) The cable drums shall be off-loaded at the site locations as identified
by the site engineer.
j) It shall be ensured that there is no obstruction to movement of vehicles
or any hindrance to works of other companies.
7.2

Cabling
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7.2.1 Underground Cable Pulling


a) Inspection of sand bed will be carried out prior to commencement of
cable pulling. The sand bed will be of minimum 100mm Thickness.
b) After commencement of cable pulling the trench will be maintained
clean.
c) Cable rollers shall be placed as required on the cable route.
d) Cable winch, if required, shall be positioned in proper place for cable
pulling.
e) The cable drum intended for cable pulling shall be identified as per that
indicated in the drum schedule.
f) The cable drums shall be un-packed.
g) The cable shall be fixed to the winch, if used, by means of a cable sock
or gripper. Required number of persons will be posted at winch and
near the drum.
h) Cable laying will generally start from one end of the route length or at
any suitable point if required.
i) In case of buildings, the drums will be placed outside the buildings and
the cable pulled in the opposite direction. After reaching the other end
the length of the cable required for reaching the location inside the
building will be measured and then cut the cable.
j) In case of cable lengths which are more than one drum length, all
cables which can be laid from original position will be completed. And
then the cable pulling set-up will be re-positioned to the next location,
from where the next length will be pulled.
k) Depending on the weight and size of the drum, suitable size of the
cable spindle shall be placed inside the central axis of the drum.
l) Suitable jacks shall be placed firmly on the ground and jacked-up to
allow clearance from the ground depending on the size of the cable
drum.
m) The drum shall be lifted by required equipment and placed on the
jacks. The cable drum will be correctly positioned and the direction of
cable pulling as indicated by arrow on the drum shall be complied.
n) Cables will be laid / pulled by hand and / or winch. During pulling with
winch, if required, the tension on the cable will not exceed that given
by the manufacturer.
o) Cables will be pulled according to drum-cable cutting schedule and as
shown in the relevant drawings.
p) Bending radius of cables shall comply with cable manufacturers
recommendation.
q) Unless the lengths exceed the maximum drum lengths joints shall be
avoided. Joint markers indicating joint positions shall be provided above
grade.
r) Before cutting the cable, both ends must be inspected to ensure
sufficient length is for proper dressing and end termination.
s) Soon after completion of every cable the cables will be tested for
insulation resistance.
t) The open ends will be sealed till termination. Cable identification tags
shall be installed soon after the cable pulling.
u) Cable tags shall be installed as per Client Specification
v) The cable schedule and drum schedule will be updated with the
information on cable pulling.

w) After completion of all cables in the same route the cables shall be
dressed and clamped.
x) Cable Joints position, if any, will be shown on the drawings.
y) Once the cable is laid, the processes listed out under 6.5 & 6.6 is
carried out.
z) Empty cable drums will be transported back to stores.
7.2.2 Above Ground Cable Pulling
a) Cables shall be laid mainly above ground in cable trays perforated and
ladder type.
b) Cable rollers shall be placed at every 6-12 meters or less if required to
avoid touching of the cable to tray.
c) Cable winch, if used, shall be positioned in proper place for cable
pulling.
d) The cable drum intended for cable pulling shall be identified as per that
indicated in the drum schedule.
e) The cable drums shall be unpacked. The cable shall be fixed to the
winch by means of a cable sock or gripper.
f) Required number of persons will be posted at the winch, if used, and
near the drum.
g) Cable laying will generally start from one end of the route length from
other suitable point if required.
h) In case of buildings, the drums will be placed outside the buildings and
the cable pulled in the opposite direction. After reaching the other end
the length of the cable required for reaching the location inside the
building will be measured and then cut the cable.
i) In case of cable lengths which are more than one drum length, all
cables which can be laid from original position will be completed. And
then the cable pulling set-up will be re-positioned to the next location,
from where the next length will be pulled.
j) Depending on the weight and size of the drum, suitable size of the
cable rolling shaft (Spindle) shall be placed inside the central axis of
the drum.
k) Suitable jacks shall be placed firm ground and jacked-up to allow
clearance from the ground depending on the size of the cable drum.
l) The drum shall be lifted by required equipment and placed on the
jacks.The cable drum will be correctly positioned and the direction of
cable pulling as indicated by arrow on the drum shall be complied..
m) Cables will be laid / pulled by hand and / or winch.
n) Cables will be pulled according to drum-cable cutting schedule and as
shown in the relevant drawings.
o) Bending radius of cables shall comply to cable manufacturers
recommendation.
p) Unless the lengths exceed the maximum drum lengths joints shall be
avoided.
q) Before cutting the cable, both ends must be inspected to ensure
sufficient length is for proper dressing and end termination.
r) Soon after completion of every cable the cables will be tested for
insulation resistance.
s) The open ends will be sealed till termination.
t) Cable tags shall be installed as per Client Specification
u) The cable schedule and drum schedule will be updated with the
information on cable pulling.
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v) After completion of all cables in the same route the cables shall be
dressed and clamped. Cables shall be fixed in horizontal or vertical
runs with or Cable ties.
w) Interval of clamping will be as per Client Specification, but will not
exceed 10Mtr for the horizontal runs and 1.0Mtr for vertical runs. When
single core cables are used the laying shall be in three-foil formation
(Trefoil).
x) As-Built mark-up drawings certified by Contractors Supervisor and
Engineer will be prepared. Cable joints position will be shown on the
drawings.
y) Empty cable drums will be transported back to stores.
a)

b)

c)
d)

7.2.3 Considerations
Where bends are encountered in a run, cables shall be lubricated with
a cable pulling lubricant to facilitate drawing in. Petroleum based is not
acceptable. During installation process cable must not be bent to a
radius of less than 12 times the overall diameter of the cable. These
conditions shall be strictly adhered to, particularly where cables turn
into road crossings, conduit entry etc.
Rollers must be used where cables are installed in an open trench using
a pulling rope and eye; cable rollers are to be used at frequent intervals
to support the cables and must never be more than 3 meters apart.
Care must be taken to ensure that the cable does not enter or leave
the rollers at an angle that exceeds the bending radius of the cable.
The rollers are to be packed securely to prevent movement. Before
driving any spikes to secure the rollers, care must be taken to avoid
other buried installations like cables etc. below the trench floor.
The Pulling rope must be equipped with a swivel and be attached to the
cable by a stocking grip with pulling eye.
The cable shall be drawn into the trench manually, before the pull
commences, to prevent the winch to move along with the cable. The
cable shall be drawn into the trench smoothly with a minimum of stops
and at an average speed of 9-12 meters per minute, to avoid irregular
movement.

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