EPC FOR INSTALLATION OF PWT, CPF

BADRA, REPUBLIC OF IRAQ

Method Statement for Rehabilitation of Pipe Culvert

Doc. No.: GB1516-SAC-240-CV-MS-0003 Rev.: B Page 1 of 19

DOCUMENT DETAILS
EMPLOYER CONTRACT NO. : 1516-23-BD-850-00
PROJECT TITLE :
EPC for Installation of PWT, Republic of Iraq

EMPLOYER : Gazprom Neft Badra B.V.

CONTRACTOR : Suhool Azmer Company. Ltd
CONTRACT JOB NO. : SAC
PROJECT DOCUMENT NO. : GB1516-SAC-240-CV-MS-0003
REVISION NO. : B No. of pages: 19
DOCUMENT DESCRIPTION :
Method Statement for Rehabilitation of Pipe Culvert

REVISION DETAILS

B Issued for Approval 16/09/2023 Hassan H. Hassoun Samer Salomy Bassim Qassim
A Issue for Review 7/09/2023 Hassan H. Hassoun Samer Salomy Bassim Qassim

REV DESCRIPTION DATE PRPD CHKD APPD

 EPC FOR INSTALLATION OF PWT, CPF
BADRA, REPUBLIC OF IRAQ
Method Statement for Rehabilitation of Pipe Culvert

Doc. No.: GB1516-SAC-240-CV-MS-0003 Rev.: B Page 2 of 19

REVISION RECORD

Rev. Para. Revision Description

A Issued for Review

B Issued for Approval

Hold No Para. Description of Hold

 EPC FOR INSTALLATION OF PWT, CPF
BADRA, REPUBLIC OF IRAQ
Method Statement for Rehabilitation of Pipe Culvert

Doc. No.: GB1516-SAC-240-CV-MS-0003 Rev.: B Page 3 of 19

Contents
1. SCOPE ....................................................................................................................................................................................... 4

2. OBJECTIVE ................................................................................................................................................................................. 4

3. DEFINITIONS AND ABBREVIATIONS ............................................................................................................................................ 4

4. CODES AND STANDARS .............................................................................................................................................................. 4

5. REFRENCESS .............................................................................................................................................................................. 5

6. ROLES AND RESPONSIBILITIES .................................................................................................................................................... 5

7. EQUIPMENTS............................................................................................................................................................................. 5
7.1 Equipment's HSE requirements .......................................................................................................................................... 5

8. SANDBLAST ............................................................................................................................................................................... 6
8.1 Materials of sand blast ...................................................................................................................................................... 6
8.2 Equipment's of sand blast .................................................................................................................................................. 6

9. MEASUREMENTS OF CORROSION AND ENFORCEMENT .............................................................................................................. 6

10. PREPARATIONS AND IMPLEMENT OF POST INSTALLED REBAR ............................................................................................... 7

10.1 Sequence of post installed reinforcements works ............................................................................................................... 8

11. QUALITY ................................................................................................................................................................................ 8

12. SAFETY .................................................................................................................................................................................. 8

13. CONCLUSION......................................................................................................................................................................... 9

14. APPENDICES ................................................................................................................................................................... 10

14.1 APPENDIX 1 – Fosroc Lokfix E75 ....................................................................................................................................... 11
14.2 APPENDIX 2 – Management Photo .................................................................................................................................. 15
 EPC FOR INSTALLATION OF PWT, CPF
BADRA, REPUBLIC OF IRAQ
Method Statement for Rehabilitation of Pipe Culvert

Doc. No.: GB1516-SAC-240-CV-MS-0003 Rev.: B Page 4 of 19

1. SCOPE

This document purpose to establish essential quality base for restoration activities specially for earth,
concrete and uncompleted works for pipe culvert through (EPC for installation of PWT) project

2. OBJECTIVE

This document specifies methods and procedure to execute the EPC for installation of PWT restoration
works safely and in accordance with construction drawing and adhering to applicable specifications
with consideration to local rules and regulations

3. DEFINITIONS AND ABBREVIATIONS

EMPLOYER Gazprom Neft-Badra B.V. (GPNB
CONTRACTOR Suhool Azmer Company. Ltd. (SAC)
Engineering Procurement Construction (EPC) for Installation of Produced Water
PROJECT
Treatment (PWT)
QA/QC Quality assurance / Quality Control
JSA Job Safety Analysis
RFI Request for inspection
MAR Material approval Request
PTW Permit to Work
PPE Personal Protective Equipment
Shall Indicates a mandatory requirement
Should Indicates that the requirement is strongly recommended to be adhered to.
ISO International Organization for Standardization
ITP Inspection And Test Plan
IFC Issued for construction

4. CODES AND STANDARS

ACI 318M Building Code Requirements for Structural Concrete
ACI 347 Guide to Formwork for Concrete
ACI 304R Guide for Measuring Mixing Transporting and Placing Concrete
ASTM C 494 Standard Specification for Chemical Admixtures for Concrete
ASTM A 615M Standard Specification for Deformed & Plain Steel Bars for Concrete Reinforcement
EN-196 Methods of testing cement
Standard Specification for Admixtures to Inhibit Chloride-Induced Corrosion of
ASTM C1582
Reinforcing Steel in Concrete

Standard Test Method for Density and Unit Weight of Soil in Place by Sand-Cone
ASTM D 1556
Method
Standard Practice for Classification of Soils for Engineering Purposes (Unified Soil
ASTM D2487
Classification System)
ASTM D4318 Standard Test Methods for Liquid Limit, Plastic Limit, and Plasticity Index of Soils
 EPC FOR INSTALLATION OF PWT, CPF
BADRA, REPUBLIC OF IRAQ
Method Statement for Rehabilitation of Pipe Culvert

Doc. No.: GB1516-SAC-240-CV-MS-0003 Rev.: B Page 5 of 19

5. REFRENCESS

GB1516-SAC-240-QA-PL-0001 QA/QC plan

GB1516-SAC-240-CV-TP-0001 Inspection and Test Plan for Civil Works
GB1516-SAC-240-CV-SP-0001 Specification for earth works
GB1516-SAC-240-CV-SP-0002 Specification for concrete works
GB1516-SAC-240-HS-PL-0001 HSE plan
GB1516-SAC-240-CV-RP-0002 Structure Analysis for Culvert

6. ROLES AND RESPONSIBILITIES

Supervisors shall be directly responsible for the monitoring the activities on site (field) and utilizing the
resources, effectively maintaining good productivity. He shall obtain relevant work permits and approved
JSA (Job Safety Assessment) as necessary and coordinate with client acceptability of cleanliness.

QA/QC engineer shall be responsible for the quality of execution for various works of the project and maintain
the quality of implemented works inside the site of work

Safety In-charge / Supervisor shall be responsible for site surveillance, reporting HSE inaction,
recommending corrective actions and ensuring site compliance with the Employer's Health Safety and
Environmental program.

Skilled Laborers shall be employed for the execution of works. They must understand the extent of works to be
executed, aware of the hazards involved, and receive relevant instructions from Supervisor who is responsible
for the activity

7. EQUIPMENTS

Contractor shall have a fleet of vehicles, Machinery and Equipment that support all operations and
duties. All vehicles, Machinery and Equipment shall comply with safety requirements and All equipment is
provided with professional certified drivers & operators.
Our team manages those vehicles professionally by applying safety inspections, third-party inspections, and the
required regular maintenance.
All drivers and operators have third-party certificates. Moreover, they have good experiences in oilfields and
engineering project.

Key Equipment Required Key Tools Required

• TANKERS. • AIR COMPRESSOR.
• TRANSPORTATION CARS. • DRILL HAMMER.
• POWER GENERATORS.
• AIR COMPRESSOR VARIOUS.

7.1 Equipment's HSE requirements

The purpose of this procedure is to ensure that specific consideration is provided while performing
the required job to avoid potential hazards / risks that could happened while operating, work with
 EPC FOR INSTALLATION OF PWT, CPF
BADRA, REPUBLIC OF IRAQ
Method Statement for Rehabilitation of Pipe Culvert

Doc. No.: GB1516-SAC-240-CV-MS-0003 Rev.: B Page 6 of 19

any mechanical equipment's, machines and instruments all vehicles and machines shall comply
with following:

➢ All vehicles shall be certified by 3rd party or tested and certified by employer HSE department.
➢ All operators and drivers shall be certified to use their specific equipment or vehicle
➢ All specific equipment's and instruments shall be calibrated with certification by 3 rd party
➢ Initial check for the performance of vehicle's, equipment and instruments shall be made by
contractor QA/QC engineer and HSE engineer separately

8. SANDBLAST

All previous rebars shall be cleaned and sand blasted from rust mud, or any other adhesive materials
to ensure that the surfaces between old and new rebar is efficient for connection.
An inspection shall be made by employer discipline engineer to confirm that the condition of rebar is
suitable and ready to be use in the other stage of reconstruction of pipe culvert.

8.1 Materials of sand blast

Sand that used in sandblasting must be free of residues, chemicals or moisture, and must have a
suitable granularity that matches the requirements of sand blasting.
Sand shall be from a source confirmed by the employer.

8.2 Equipment's of sand blast

All equipment that used in sand blasting shall matches the requirements of employer HSE System
to avoid any hazards/risk that could happen while implementing.
Initial check shall be made by contractor HSE staff to ensure that these equipment's are qualified to
be used inside the project field.

9. MEASUREMENTS OF CORROSION AND ENFORCEMENT

After sand blast is done and confirmed the steel shall be measured by specialized engineer from
contractor side to estimate the percentage of occurred corrosion in the rebar steel
Compensation of the steel shall be according to ACI standard
Calculations of post installed rebar

The consolidation of structural part for pipe culvert shall be according to ACI 364-10T-14
These calculations were made according to several measured samples from site
The following calculation representing the actual condition of existed rebar in pipe culvert:
C: section
D: diameter
O: origin
Origin area (AO) = 0.785*D2
 EPC FOR INSTALLATION OF PWT, CPF
BADRA, REPUBLIC OF IRAQ
Method Statement for Rehabilitation of Pipe Culvert

Doc. No.: GB1516-SAC-240-CV-MS-0003 Rev.: B Page 7 of 19

Current area (AC) = 0.785* D2

Area lost (AL) = Ao – Ac
Lost area percentage = area lost (AL) / origin area (AO)

Sample #1
D1c= 10.66mm
D2c= 10.92mm
Dc= (10.66+10.92) / 2 = 10.79mm
(AO) = 113.04mm2
(AC) = 91.393mm2
Area lost (AL) = 113.04 - 91.393 = 21.647 mm2
Lost area percentage = (21.647/ 113.04) * 100 = 19.149 assume 20%

Sample #2
D1c = 9.49mm
D2c = 10.55mm
Dc = (9.49+10.55)/2 =10.02 mm
(AO) = 113.04 mm2
(AC) = 78.814 mm2
Area lost (AL) = 113.04 – 78.814 = 34.225 mm2
Lost area percentage = (34.225/ 113.04) * 100 = 30.27 mm2 assume 31%

10. PREPARATIONS AND IMPLEMENT OF POST INSTALLED REBAR

➢ Drill locations to the proper size, ensuring it is larger than the rebar diameter by at least 4mm
and a depth of 110mm, using a drill hammer. This is to ensure that the position is suitable for
epoxy and reinforcement, as per the instructions in Table 3 of the setting parameters in
Appendix 1.
➢ After drilling, all holes must be cleaned thoroughly. Utilize an air compressor or a suitable blower
to remove dust, debris, and any other materials.
➢ Fill the holes with epoxy material that meets the project's requirements and specifications
(GB1516-SAC-240-CV-SP-0002, para 26.1). The designated material for this purpose is
(Fosroc – Lokfix E75), as indicated in Appendix 1.
➢ Prior to use, steel reinforcement shall undergo testing in accordance with either ISO-6935-
2:2019 or ASTM A615 standards.
➢ All cutting, bending, and installation of reinforcements must align with the IFC drawings and
meet the required specifications.
➢ Secure the rebar into the holes with the appropriate depth, ensuring they are properly aligned
with each other without any defects or damages.
 EPC FOR INSTALLATION OF PWT, CPF
BADRA, REPUBLIC OF IRAQ
Method Statement for Rehabilitation of Pipe Culvert

Doc. No.: GB1516-SAC-240-CV-MS-0003 Rev.: B Page 8 of 19

10.1 Sequence of post installed reinforcements works

1- Survey for positions of post installed rebar
2- Marking the positions for rebars
3- Drilling with suitable drill
4- Cleaning with a brush
5- Cleaning with air
8- Epoxy application
9- Placing the new reinforcement rebar

11. QUALITY
QA/QC manager and engineers shall maintain the quality of execution step by step and the always
must keep good coordinating with site supervisor and engineers.
Any activity shall not be proceeded prior RFI and approval of employer as per inspection and test
plan
All documents that relate to the construction shall be prepared already to ensure the level of quality
All test shall be made according to the specifications and requirements of Quality plan

12. SAFETY
Work to be carried out safely and accordance with the HSE program and Safety Policy. Site
operatives shall be well inducted for the safe operation of the machinery,
equipment and tools to be used.
• Safe access and Safe working area shall be maintained.
• Safe lifting and placing of steel components.
• Stability and structural adequacy of the part-erected structure.
• Personnel protective equipment will be used by all staff and labors.
The minimum personnel protective equipment is as follows:
➢ Safety Helmet.
➢ Safety footwear.
➢ Eye protection.
➢ Full body safety harness.
➢ High visibility vest
➢ Safety gloves
• Any other equipment required by the site operator or deemed necessary by the task.
• All regulation implemented by authority at site will be considered.
• Proper barricades and traffic signs shall be placed around the work site location wherever
required.
 EPC FOR INSTALLATION OF PWT, CPF
BADRA, REPUBLIC OF IRAQ
Method Statement for Rehabilitation of Pipe Culvert

Doc. No.: GB1516-SAC-240-CV-MS-0003 Rev.: B Page 9 of 19

13. CONCLUSION

As per the analysis provided in the Structure Analysis for culvert GB1516-SAC-240-CV-RP-0002
on page seven, it has been concluded that a minimum embedment percentage of 21% is required
(Percentage (%) = ( ρmin / ρact ) * 100).
To prioritize safety and take necessary precautions, an additional ten percent will be added, resulting
in a required embedment percentage of 31%.

Figure 1 (New Post-Installed Reinforcement Scheme)

 EPC FOR INSTALLATION OF PWT, CPF
BADRA, REPUBLIC OF IRAQ
Method Statement for Rehabilitation of Pipe Culvert

Doc. No.: GB1516-SAC-240-CV-MS-0003 Rev.: B Page 10 of 19

14. APPENDICES
APPENDIX 1 – Forsook Lok fix E75
APPENDIX 2 – Management Photo
 EPC FOR INSTALLATION OF PWT, CPF
BADRA, REPUBLIC OF IRAQ
Method Statement for Rehabilitation of Pipe Culvert

Doc. No.: GB1516-SAC-240-CV-MS-0003 Rev.: B Page 11 of 19

14.1 APPENDIX 1 – Fosroc Lokfix E75

 EPC FOR INSTALLATION OF PWT, CPF
BADRA, REPUBLIC OF IRAQ
Method Statement for Rehabilitation of Pipe Culvert

Doc. No.: GB1516-SAC-240-CV-MS-0003 Rev.: B Page 12 of 19

 EPC FOR INSTALLATION OF PWT, CPF
BADRA, REPUBLIC OF IRAQ
Method Statement for Rehabilitation of Pipe Culvert

Doc. No.: GB1516-SAC-240-CV-MS-0003 Rev.: B Page 13 of 19

 EPC FOR INSTALLATION OF PWT, CPF
BADRA, REPUBLIC OF IRAQ
Method Statement for Rehabilitation of Pipe Culvert

Doc. No.: GB1516-SAC-240-CV-MS-0003 Rev.: B Page 14 of 19

 EPC FOR INSTALLATION OF PWT, CPF
BADRA, REPUBLIC OF IRAQ
Method Statement for Rehabilitation of Pipe Culvert

Doc. No.: GB1516-SAC-240-CV-MS-0003 Rev.: B Page 15 of 19

14.2 APPENDIX 2 – Management Photo

 EPC FOR INSTALLATION OF PWT, CPF
BADRA, REPUBLIC OF IRAQ
Method Statement for Rehabilitation of Pipe Culvert

Doc. No.: GB1516-SAC-240-CV-MS-0003 Rev.: B Page 16 of 19

 EPC FOR INSTALLATION OF PWT, CPF
BADRA, REPUBLIC OF IRAQ
Method Statement for Rehabilitation of Pipe Culvert

Doc. No.: GB1516-SAC-240-CV-MS-0003 Rev.: B Page 17 of 19

 EPC FOR INSTALLATION OF PWT, CPF
BADRA, REPUBLIC OF IRAQ
Method Statement for Rehabilitation of Pipe Culvert

Doc. No.: GB1516-SAC-240-CV-MS-0003 Rev.: B Page 18 of 19

 EPC FOR INSTALLATION OF PWT, CPF
BADRA, REPUBLIC OF IRAQ
Method Statement for Rehabilitation of Pipe Culvert

Doc. No.: GB1516-SAC-240-CV-MS-0003 Rev.: B Page 19 of 19