Pearl GTL

Project
Shell Project No: HP-3000-QAT
Project Document Number: T- 4.234.074

Purchase Order Number:

2MH127

Tag/Item Number(s):

N/A

Unit(s):

ASU

PCWBS:

LINDE ENGINEERING

Contractor Project No :
Project Rev.: B

Page 2 of 16

5887

QATAR SHELL GTL PROJECT (PEARL)

C2 AIR SEPARATION UNITS CONSTRUCTION

29.01.2008

Ready For Construction

SB

UA/MC

ZG

RFC

25.11.2007

Company Comments Incorporated

IU

UA/IO

MC/ZG

CCI

02.10.2007

Issued for Company Comments

IO

MC

ZG

ICC

29.09.2007

Issued for Company Comments

IO

MC

ZG

ICC

15.09.2007

Issued for Review

IO

MC

ZG

IFR

Issued for Internal Review

IO

MC

ZG

IIR

B1
A1
GAMA
Rev.
No.

Project
Rev
No.

Date

Prepared Checked Approved

By
By
By
ORIGINATOR

Description

Status

Document Title:

METHOD STATEMENT FOR BACKFILLING WORKS

LINDEGINEERING AG
Document No.

Contractor

Gama Qatar Co. W. L. L.

LOC 470
GAM

MTS

CIV

GTL

008

Org.
Code

Doc.
Type

Disc.
Code

Geogr.
Area

Seq.
No

Rev.
No

Project Document Number: T-4.234.074

Vendor Code

Rev No: B

Q A T A R

Doc. Title

GAM-MTS-CIV-GTL-008 Rev. F
Method Statement for Backfilling Works

Date

29.01.2008

TABLE OF CONTENTS
1.

INTRODUCTION _______________________________________________________________5

2.

DEFINITIONS _________________________________________________________________5

3.

REFERENCES _________________________________________________________________5

4.

HSSE _________________________________________________________________________6

5.

RESOURCES ___________________________________________________________________7
5.1.

Responsibility _____________________________________________________________________7

Civil Works Manager ____________________________________________________________________________ 7

QA/QC Management_____________________________________________________________________________ 7
HSSE Manager _________________________________________________________________________________ 7
Site Engineer / Supervisor _________________________________________________________________________ 7

6.

5.2.

Equipment ________________________________________________________________________7

5.3.

Manpower ________________________________________________________________________7

METHOD OF EXECUTION ______________________________________________________8

6.1.

General __________________________________________________________________________8

6.2.

Trials ____________________________________________________________________________8

6.3.

Backfilling Works __________________________________________________________________9

6.3.1.
6.3.2.

7.

Pre-Commencement Works ______________________________________________________________ 9

Execution ___________________________________________________________________________ 10

TESTING _____________________________________________________________________11
7.1.

Introduction _____________________________________________________________________11

7.1.1 General _________________________________________________________________________________ 11

7.1.2 Scope __________________________________________________________________________________ 11

7.2.
7.2.1
7.2.2
7.3
7.4
7.5

Sampling & Testing _______________________________________________________________12

Sampling Procedure from Stockpile _________________________________________________________ 12
Sampling Procedure from Laid Material______________________________________________________ 12
TESTING FREQUENCY _________________________________________________________________ 13
TEST RESULTS________________________________________________________________________ 13
MATERIAL SPECIFICATIONS ___________________________________________________________ 13

8.

QUALITY ASSURANCE / QUALITY CONTROL ____________________________________13

9.

ATTACHMENTS_______________________________________________________________13
9.1.

Job Safety Analysis________________________________________________________________13

T-4.234.074 Rev. B

Page 4 of 16

Q A T A R

Doc. Title

GAM-MTS-CIV-GTL-008 Rev. F
Method Statement for Backfilling Works

Date

29.01.2008

1. INTRODUCTION
This document describes the methods proposed to be used for the Backfilling operations that shall be
carried out as part of the Air Separation Unit Construction Works for Qatar Shells Pearl GTL Project in
Ras Laffan Industrial City in the State of Qatar.

2. DEFINITIONS
Company

QSGTL or its PMC

Contractor or Linde

Linde Engineering AG

Subcontractor or Gama

Gama Qatar Co. W. L. L.

QCP

Quality Control Procedure

QCR

Quality Control Record

ITP

Inspection and Test Plan

QA/QC

Quality Assurance / Quality Control

RLIC or RLC

Ras Laffan Industrial City

JSA

Job Safety Analysis

HSSE

Health, Safety, Security and Environmental

3. REFERENCES
Qatar Construction Standard
T.4-095.955

Project HSSE Program Overall

T.4-095.303

Project HSSE Construction Plan

T.4-129.849

Permit to Work Procedure

T.4-129.851

Excavation Procedure

T-13.376.490

Project Specific Specification for Site Preparation

DEP 34.11.00.11

Site Preparation and Earthworks including Tank Foundations and Tank Farms

T-13.376.352

Amendments and/or Supplements to Site Preparation and Earthworks including

Tank Foundations and Tank Farms

T-4.234.144

QC Documents for Site Preparation and Earthworks

T-4.234.074 Rev. B

Page 5 of 16

Q A T A R

Doc. Title

GAM-MTS-CIV-GTL-008 Rev. F
Method Statement for Backfilling Works

Date

29.01.2008

4. HSSE
All works shall be in compliance with the State of Qatar laws and regulations, Ras Laffan Industrial City
and international standards/codes, and Company and Contractor requirements and instructions.
All personnel will go through Gama, Linde and Company Safety Induction courses as well as other
trainings as identified by their supervisor. Please see Document Number GTL-GM-001-A-5635 for
details.
A Job Safety Analysis (JSA) specific for this work including a Risk Assessment, is prepared as per
Gama procedure GTL-GM-001-A-5626 and is attached herein. Such JSA addresses the hazards
associated with each task within the scope of this Method Statement and introduces the controls that
will be implemented to reduce the associated risks to acceptable levels. The JSA will be used by the
Site Supervisor as the basis of his TSTI / TSTO and Toolbox Talks.
All personnel will have PPE required for their specific tasks in addition to the minimum PPE (coveralls,
safety goggles, safety shoes, high-visibility vests, gloves) at site at all times as required.

T-4.234.074 Rev. B

Page 6 of 16

Q A T A R

Doc. Title

GAM-MTS-CIV-GTL-008 Rev. F
Method Statement for Backfilling Works

Date

29.01.2008

5. RESOURCES
5.1.

RESPONSIBILITY
Civil Works Manager

The Civil Works Manager is responsible for the overall management of the project construction team to
ensure that safe and effective operations are conducted and properly documented.

QA/QC Management
QA/QC Department shall ensure quality and compliance during all phases of the construction.

HSSE Manager
Responsible for the safety control works for all construction sites under the jurisdiction of his
department, HSSE Manager will advise the site on all safety policies, plans, procedures, etc. He will
also be involved in the preparation of the JSA as an advisor and will ultimately approve the same.

Site Engineer / Supervisor

The site engineer/supervisor will perform the necessary studies and calculations and will supervise
procedures. He will ensure that the work is being carried out effectively in accordance with the
established Method Statements and JSA.

5.2.

EQUIPMENT

Equipment planned for backfilling works is as follows:

Dozer

Plate Compactor (if needed)

Grader

Dewatering Pumps (if needed)

Rollers

Dump Trucks

Water Tanker

The number of equipment will be determined according to the work progress and conditions on site.

5.3.

MANPOWER

Operation crew for backfilling works shall be formed as follows:

Site Engineer / Supervisor

Surveyors

Foremen

Survey Helpers

HSSE Officers

Pump Operators

Operators

Flagmen / Banksmen

Drivers

Common Laborers

The number of personnel will be determined according to the work progress and conditions on site.

T-4.234.074 Rev. B

Page 7 of 16

Q A T A R

Doc. Title

GAM-MTS-CIV-GTL-008 Rev. F
Method Statement for Backfilling Works

Date

29.01.2008

6. METHOD OF EXECUTION
6.1.

GENERAL

The material to be used is the material that has been excavated and stockpiled before and the material
to be imported. In order to ensure the quality of the material, it shall be tested to ensure compliance with
the specification requirements. One test set shall comprise of following test:

Particle Size Distribution,

Soil classifications

Maximum Dry Density Optimum Moisture Content.

The water to be used for compaction shall be potable water; and in no case shall seawater or
groundwater be used for compaction.
The amount of water to be used shall be determined from the tests performed on materials taking past
experiences with similar operations into account.
The approximate quantities for Type-A, Type-B and Excavated materials (excluding road works) are as
follows:
Type-A:

~1000m3

Type-B:

~1000 m3

Excavated Material

~1000 m3 (if suitable to use as backfill material)

6.2.

TRIALS

Compaction trials shall be performed in accordance with Appendix 1 of DEP 34.11.00.11-Gen to

determine the optimum moisture content of fill material (Type-A, Type-B and Excavated Material), depth
of layers of fill and the number of passes necessary to achieve the required compaction prior to the start
of any backfilling activities. Location of such trials will be verified during the first site activities.

T-4.234.074 Rev. B

Page 8 of 16

Q A T A R
6.3.

Doc. Title

GAM-MTS-CIV-GTL-008 Rev. F
Method Statement for Backfilling Works

Date

29.01.2008

BACKFILLING WORKS

6.3.1. Pre-Commencement Works

All personnel shall be trained and all equipment shall be inspected and approved prior to the start of
work.
All the equipment operators shall be qualified and tested eventually trained before their employment.
Prior to the commencement of backfilling operations, the bottom of the excavation shall be graded by a
Grader or a Dozer in order to remove loose and muddy material from the surface whenever needed.
For narrower areas where a Dozer or a Grader cannot fit into the excavation, the area shall be
excavated wider to allow the entrance of the required equipment to the excavation bottom. The overexcavated areas shall be treated as per the project specifications.
After the suitability of the excavation bottom for filling is confirmed by a Linde and/or Company
representative, if applicable, slopes shall be formed towards the drainage ditches provided at the sides
of the pit.
Following the completion of necessary documentation as per ITP and upon authorization by Linde
and/or Company, backfilling works shall commence.
Road and yard base-course backfilling using excavation materials includes material selection, loading,
transportation from stock, placement and compaction in layers as stated in method statement ( T-4-234070, T-4-234-564)
Depending on the nature of the filling pit and the conditions at site, drainage side-channels may be
provided.
Generation of dust shall be controlled as per approved specifications and past experience.
Laboratory tests shall be carried out on the material before backfilling and on the fill after the backfilling.
Such tests will be carried out by a third party, or under the supervision of an independent specialist.

T-4.234.074 Rev. B

Page 9 of 16

Q A T A R

Doc. Title

GAM-MTS-CIV-GTL-008 Rev. F
Method Statement for Backfilling Works

Date

29.01.2008

6.3.2. Execution
1)

Haulage

The fill material shall directly be dumped onto the platform, through which access roads shall be
provided from various directions as per the need, and be laid to a loose thickness of not exceeding 225
(Type-A), 300mm (Type-B) or 600-mm (Excavated Material), leaving the side ditch open for drainage.
2)

Watering

After the material is laid in a loose layer, it shall be moisturized by water bowsers in order to achieve
required level of compaction. The water to be used shall be potable water, which is to be obtained from
an approved source.
3)

Laying and Compaction

As the material is laid and moisturized, it shall be compacted by compaction equipment, which shall
mainly consist of Rollers. Each layer shall be compacted to the specified percentage of maximum dry
density obtained according to ASTM D 1557.
Laying and compaction of the material shall be carried out in this fashion by layers of not exceeding
225, 300 or 600 mm loose thickness (depending on the type of material) throughout the area. When
the elevation top of layers reaches 2 ~ 3 layers above the existing grade, the drainage ditch shall be
filled with Type-C (or excavated) material or similar and be compacted using bulldozers and/or other
types of grading equipment.
Compaction will be done as per Specific Specification for Site Preparation (T-13.376.490) for Type-A
and Type-B materials; whereas laying and compaction of excavated material shall comply with the
requirements of Type-C material as indicated in said document.
4)

Survey Report

When the backfilling reaches its final elevation within the tolerance limits set out in the Site Preparation
and Earthworks DEP, a survey report shall be prepared; and the area shall be handed-over to the
Contractor after the necessary documentation have been prepared.

T-4.234.074 Rev. B

Page 10 of 16

Q A T A R

Doc. Title

GAM-MTS-CIV-GTL-008 Rev. F
Method Statement for Backfilling Works

Date

29.01.2008

7. TESTING
7.1.

INTRODUCTION
7.1.1 General

Laboratory operations involve sampling of fill materials, testing of the same and reporting of the results.
Laboratory operations shall be carried out by a 3rd Party Laboratory approved by Linde and/or the
Company. Laboratory subcontractor shall establish a site laboratory capable of carrying out Field
Density Tests, and other tests if required. Samples shall be transported to the Laboratory when
required for carrying out tests that cannot be handled by the Site Laboratory. The sampling procedure
is discussed in Section 7.2.

7.1.2 Scope
Following tests shall be carried out in the laboratory in accordance with the below-listed standards
during the course of the backfilling works:

Test

Standard

Test Location:

Particle Size Distribution

ASTM D 422

to be decided

Soil Atterberg Limits

ASTM D 4318

to be decided

Maximum Dry Density & Optimum Moisture Content

ASTM D 1557

to be decided

Moisture Content

ASTM D 2216

to be decided

Field Density Test (CBR)

ASTM D 1556

Site

As an alternative, Nuclear Density Probe Testing may be used for field density testing, should it be
deemed feasible. Should this be the case, all Company and Contractor procedures regarding the
handling and storage of Nuclear Devices will be followed. Moreover, trail tests will be done and
submitted to the Contractor and/or the company prior to work commencement to ensure that the device
is calibrated and suitable for the task.

T-4.234.074 Rev. B

Page 11 of 16

Q A T A R
7.2.

Doc. Title

GAM-MTS-CIV-GTL-008 Rev. F
Method Statement for Backfilling Works

Date

29.01.2008

SAMPLING & TESTING

Sampling shall be carried out as per ASTM D 75.

7.2.1 Sampling Procedure from Stockpile

Sampling of fill materials for classification tests shall be taken from the stockpiles at site under the
supervision of QA / QC Department of GAMA Qatar. CONTRACTOR shall be notified before each
sampling, so that Linde and/or Company representatives can attend and inspect any sampling
operation.
Sampling from the stockpiles shall be made up of at least three increments taken from the top third, at
the mid-point, and at the bottom third of the volume of the pile. For coarse or mixed material, the
services of a front-end loader should be enlisted to develop a separate, small sampling pile composed
of materials drawn from various levels and locations in the main pile after which several increments may
be combined to compose the field sample.
The amount of the sample must be predetermined on the type and number of tests to which the
material obtained to provide for the proper implementation of the test.
The quarry shall keep the material at a stockpile area dedicated to the Project in piles at the size of
each testing batch. The activities in the quarry shall frequently be inspected by a supervisor. Materials
shall be transported to the site after ensuring their compliance with the specification requirements.
Testing will be carried out as per Project Specific Specification for Site Preparation (T-13.376.490).

7.2.2 Sampling Procedure from Laid Material

Sampling from the laid material should be taken at marked areas basis and collect the whole sample
from each marked location. Representatives of Linde and/or Company can attend the sampling
whenever deemed necessary. The quarry shall be informed before to stock the material one designated
area not to let to any confusion.
The amount of the sample must be predetermined on the type and number of tests to which the
material obtained to provide for the proper implementation of the test.
Testing will be carried out as per Project Specific Specification for Site Preparation (T-13.376.490).

7.2.3

Water

Water required for compaction shall be within specified limit as specified in T-13-375-490 section 10.6.
sea water will not be used for compaction. Water will be clean and free from foreign matters. Otherwise
water will be taken from the approved sources by the Contractor/Company.

T-4.234.074 Rev. B

Page 12 of 16

Q A T A R

Doc. Title

GAM-MTS-CIV-GTL-008 Rev. F
Method Statement for Backfilling Works

Date

29.01.2008

7.3 TESTING FREQUENCY

Testing of materials shall be carried out as per the Site Preparation and Earthworks ITP and DEP.
Testing frequencies shall be at least one test per:

1000-m3 of loose material (Classification Tests, consisting of Particle Size Distribution, Atterberg
Limits and Compaction Tests) which roughly equals to 1000-m3 of material

300 and 750 m2 of compacted fill layer (Field Density Tests) for Type-A and Type-B.

Water shall be checked for chlorides, sulphates, PH, and total solid test once a day / source
change or will be taken from approved sources.

Classification Tests shall consist of Particle Size Distribution (Gradation), Atterberg Limits (Plasticity)
and Maximum Dry Density & Optimum Moisture Content (Compaction) tests.

7.4 TEST RESULTS

Preliminary results of the in-situ density tests will be declared on site as soon as the test procedure is
complete. The original test results will be prepared in the office and checked for accuracy before official
release. The computer software results will be sent by fax or email on daily basis. Computerization of
the test results will ensure optimum quality of reporting and presentation.
The in-situ density test results form must be signed by all parties upon finishing of the test.
A copy of test results approved and released by laboratory will be kept in a safe filing system and
maintain one copy at site office, just in case the Company or the Contractor needs to verify or check the
previous results.

7.5 MATERIAL SPECIFICATIONS

The materials will be compliant with Section 10 of Project Specific Specification for Site Preparation (T13.376.490). All materials will be submitted for approval (Material Approval Request) prior to use.

8. QUALITY ASSURANCE / QUALITY CONTROL

A Quality Assurance System shall be operated conforming to related standards. Controls and checks
shall be established and documented through T-4.234.144.

9. ATTACHMENTS
9.1.

JOB SAFETY ANALYSIS

T-4.234.074 Rev. B

Page 13 of 16

Q A T A R

JOB SAFETY ANALYSIS FORM

JSA For: T-4.234.074

NEW
Job being analysed: Backfilling
Department/Section doing JSA: HSSE & Construction
Normal Approvals:
JSA by:

Page No: 1 of 3

REVISED

Name

JSA Members:
Job Performers:
Signature

Date

Job Supervisor:
Additional Approvals (Determined by Job Supervisor in correlation with Linde HSSE Manager).
Name
Signature
Discipline Superindent (Linde)

Date

General job requirements / Common Personal

Protective Equipment.
1. The following Personal Protective
Equipment shall be worn:
Approved coveralls, safety glasses, safety
helmet, safety shoes and gloves.

HSSE Representative (Linde)

2.Permit To Work.

OTHERS (List Below):

Approval required for hazardous work detailed in the Linde Work Permit Procedure.
Changing conditions and emergency procedures
Stop work. Switch off equipment.Supervisor directs personnel to nearest and safest muster point considering wind direction. Supervisor counts all employees. Missing
employees are reported to Linde HSSE Dept. When all clear is given, check with Linde HSSE before returning to work.
LINDE EMERGENCY TELEPHONE NO.

HSSE MANAGER:
Pearl HOT LINE :

JOB SAFETY ANALYSIS / RISK ASSESSMENT

FOR T-4.234.074

Q A T A R

HAZARDS / POTENTIAL
ITEM
ACTIVITY
CONSEQUENCES
1 Before start the work 1.1 Unauthorised entry.

Initial Risk
RISK
P C
RANK

1.2
1.3
2

Material Hauling.

2.1

2.2

Tire puncture
Maintenance & Repair
inside.
Collision of equipment

Vehicle collision while

travelling.

2.4

Rock falling down from

dump trucks.

LOW

LOW

MED

LOW

LOW

LOW

Speed.

Residual Risk
MAIN
CONTROLS
1.1.1 Working area shall be barricaded and
secure by watchman.

ADDITIONAL
CONTROLS

LOW

Injuries due to accidents

2.3

2.5

SCOPE :
BACKFILLING

MED

1.1.2
1.1.3
1.2.1
1.3.1

Safety sign board placed.

Toolbox meeting.
Daily checking the machine.
Providing the maintenance area (not
to let any spillage).
2.1.1 Provision of sufficient banksmen for 2.1.1.1 Driver competency check.
2.1.1.2 All drivers shall have valid Qatari
working equipment.
driving licenses, all operators shall
2.1.2 Carrying out the all traffic regulations.
have 3rd party certifications.
2.1.3 Safe access shall be maintained at
site for vehicles and equipment.
2.2.1 Use of seatbelts by operators other
appropriate PPE.
2.2.2 First Aid Team and nurse with clinic.
2.2.3 Audible reversing alarms on all
vehicles & equipment.
2.3.1 Training for drivers about the traffic
regulations and speed limits.
2.3.2 Audible reversing alarms should be
installed on all vehicles and
equipment
2.4.1 Dump trucks must be covered.

2.3.1.1 Driver competency check.

2.4.2 Carrying out the all traffic regulations.

2.5.1 Driver shall be trained.

2.5.2 Driver shall be paid for days they
have worked, not for trips they have
completed in attempt to prevent any
rush.
2.5.3 Following all road and traffic
regulations.

2.5.1.1 Driver competency check.

2.5.1.2 All drivers shall have valid Qatari
driving licenses, all operators shall
have 3rd party certifications.

LOW

LOW

LOW

LOW

LOW

LOW

LOW

LOW

JOB SAFETY ANALYSIS / RISK ASSESSMENT

FOR T-4.234.074

Q A T A R

ITEM
2

ACTIVITY
Material Hauling
(CONTINUED)

HAZARDS / POTENTIAL
CONSEQUENCES
2.6 The dumptruck turn
upside down.

Initial Risk
RISK
P C
RANK

Residual Risk

2.6.1

MED

2.6.2
2.6.3

2.7

2.8

Watering

3.1

Dust.
B

LOW

LOW

Obstacle on the road.

2.7.1
2.7.2
2.8.1
2.8.2
3.1.1.

Collision of equipment.
D

MED

3.1.2
3.1.3

3.2

Dust.

3.2.1
B

3.3

Laying and
Compaction

Field density test.

4.1

Obstacle on the road.

2

LOW

Reversing and unloading.

4.2

Injuries due to collisions.

4.3
4.4

Noise.
Vibration.

5.1

Heat Stress.

LOW

LOW

LOW

LOW

3.3.2
4.1.1
4.1.2
4.2.1
4.2.2
4.3.1
4.4.1
5.1.1
5.1.2

5.2

LOW
3.2.2
3.3.1

B
4

MED

Back pain.
B

LOW

SCOPE :
BACKFILLING

MAIN
CONTROLS
Dumptrucks drivers must be ensure
that their dump bodies are fully
lowered before any movement.
Warning and training the driver on
not be hurry.
A competent and experience
supervision will be provided.
Providing dust mask.
Watering the around for dust
prevention.
Clearance the road and leveling the
road.
Placing signboards.
Provision of sufficient banksmen for
working equipment.
Audible reversing alarms on all
equipment.
Safe access shall be maintained at
site for vehicles and equipment.
Providing dust masks and urging
use.
Water spraying for dust prevention.
Clearance the road and leveling the
road.
Placing signboards.
Operator alert reverse alarm.
Banksman with visible vest will give
signal to operator or driver.
Reverse alarm shall be provided.
Training the operator .
Provide ear protection (earplugs).
Prevent storage of loose soil near the
compaction area.
Providing shade.
Locate water close to work activities.

5.1.3 Giving rest time.

5.1.4 Proper implementation of Heat
Stress Prevention Program. Drink
plenty of water.
5.2.1 Employess shall use lifting
techniques lift with legs not their
backs. Get help when needed.
5.2.2 Not allow to carry heavy loads or
sample package.

ADDITIONAL
CONTROLS
2.6.1.1 Dumping will be done on a level
ground surface.
2.6.1.2 Do not run truck while dump box is
in dumping position.

3.1.1.1 Driver competency check.

3.1.1.2 All drivers shall have valid Qatari
driving licenses, all operators shall
have 3rd party certifications.

4.2.1.1 Enforcement of traffic regulations.

LOW

LOW

LOW

LOW

LOW

LOW

LOW

LOW

LOW

LOW

LOW

LOW

5.1.1.1 Monitor the Heat Stress Flag; in

case of Black Flag all work should
stop.

5.2.1.1 Cover manual handling in Daily

Toolbox Talk.