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METHOD STATEMENT

SKY ORYX JOINT VENTURE

Installation of Cable TrayslMash Tray
CONTRACTOR'S VERIFICATION STAMP
PURSUANT TO SPECIAL CONDITION 5, WE, SKY ORYX JOINT VENTURE, VERIFY THAT THIS SUBMITTAL SATISFIES ALL
REQUIREMENTS OF THE CONTRACT, WlTH THE EXCEPTION OF THE FOLLOWING CLARIFICATIONS I PROPOSALS ACCEPTED
BY THE ENGINEER:
CONTRACTOR'S PROJECT MANAGER:
M.HORIKAWA
PRINT NAME

OddW
DATE

SIGNATURE

G , Zvb3

DOCUMENT REVIEW STATUS

STATUS 1: WORK MAY PROCEED.
STATUS 2: REVISE & RESUBMIT. WORK MAY PROCEED SUBJECT TO INCORPORATION OF COMMENTS INDICATED
STATUS 3: REVISE 8 RESUBMIT. WORK MAY NOT PROCEED.
STATUS 4: REVIEW NOT REQUIRED. WORK MAY PROCEED.
PERMISSION TO PROCEED SHALL NOT CONSTITUTE ACCEPTANCE OR APPROVAL OF DESIGN DETAILS, CALCULATIONS,
ANALYSES, TEST METHODS, OR MATERIALS DEVELOPED OR SELECTED BY CONTRACTOR AND SHALL NOT RELIEVE
CONTRACTOR FROM FULL COMPLIANCE WlTH THE CONTRACT TECHNICAL SPECIFICATIONS AND DRAWINGS.

..............................
Overseas Bechtel, Inc.

-----------------Date

Method Statement No: 25045-A1000-18-3GS-T-003

Issued by: SKY ORYX JOINT VENTURE

SKY ORVX

JWNT VENTURE

Submittal: 25045-A1 000-1 8-3GS-T007-Rev1

Method Statement: Installation of Cable TrayIMash Tray
Date on Previous Submittal: 15JUNE2007
Date on OBI Comments Returned: 29JUNE2007
Date on Reply to 081 Comments: 30SEP2007
Comment
Number
1

Section
Reference

Reviewer

OBI Comment

SOJV Reply

General
Comment

GS

Tray acceptable. T-junctions

unacceptable as well as corner junctions
does not conform to a sweeping bend
radii for cables and could cause damage
to cables.
Include method of how the tray will cross
expansion joints.

Method changed, please

check appendix 6.4, 6.5,

General
Comment

GS

6.6
Will be included later.

Adds or Changes on REV1

umber
1
2
3

section ~eference

General Notes, Span

General Notes, Wall Support
Hunger Support System for Cable TrayIMash Tray

SOJV

Hunger Support System for Cable TraylMash Tray

Removed.
Installation of Hanger Threaded
Rod Support part added.
Revized
Fastening of Support

Appendices

- Revized Manufacturer's

Catalouge/lnstallation Guide, Risk

Assesment Form.
-Added Load Calculations.

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TABLE OF CONTENTS
1. TITLE.

2. SCOPE OF WORK
General description.
Plant and equipment.
Materials.
Site planning & preparation
Work methodology.
Organisation, Responsibilities & Supervision.
Work Force.

3. HEALTH & SAFETY

Risk assessments
NDlA E S & H Contractor Requirements
Protective & Safety Equipment.
Contractual Requirements.
Information to personnel.
Emergency Procedures.
Permit Requirements.

4. ENVIRONMENTAL ISSLlES
Environmental Impact assessment.
NDlA E S & H Contractor Requirements
Contractual Requirements.
Emergency Procedures.

5. QUALITY ASSURANCE
Contractual Requirements.
Critical works.
Inspection & Testing.
Follow up & Evaluation.

6. APPENDICES
Manufacturer's Catalogue/lnstallation Guide
Risk Assessment Form
Load Calculations

Method Statement No: 25045-A1000-18-3GS-T-003

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1.

Cable Trays

2.

Scope of Work
The intent of this method of statement is to describe the steps involved in the installation of
Cable TraysIMash Trays.

General Description
This work method and procedure establishes the manner or process in which installations for
Cable Trays for building services will be completed under this contract. Installations will be
located as shown on the approved construction drawings and as detailed here and in the
specifications applicable. This scope of work covers all the items that insisted under the
specifications 25045-18-3PS-16139. Besides this document we refer to manufacturer's
catalogue Appendixes 6.

Plant and Equipment

For mesh trays installation;

Hand Tools
Power Saws
Drills
Cutters
Bolt cutter for mesh trays

Materials

Mesh trays.
Accessories such as e.g. joints, couplings, fittings.
Hanger Threaded Rod with nut and washer
Unistrut Clamp
Unistrut Channel
Expansion Anchor
Beam Clamp
Deliveries will be handled at the site area according to the given instructed requirements.

Site Planning & Preparation

Site Engineer and supervisor will ensure that necessary materials, complete tools, and
equipment for the installation are available at the site prior to work commencement. Ensure
all materials are approved for installation before works start. All approved submittals,
drawings and ITP's, are on hand for review by OBI.
A valid permit to excavate will be maintained at all times if needed.
2.4.1 Work Coordination

Supervise the work closely

Daily monitoring the work closely
Daily contact with the SOJV QAlQC Inspector
Liaise with other contractors on overlapping tasks

Method Statement No: 25045-A1000-18-3GS-T-003

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In case of any interface issue with other contractor on site,

Call CP18 Interface Manager Mr.George Yousef (Ph: 5808797) or
Mr Fatih Ulu 5823799

2.4.2 Traffic Management

Traffic management is not applicable for the application defined.

2.4.3 Permits & Certificates

Vehicle Entry Pass
Defensive Drive Permission
Permit to work
Confined space permit
Lockout & tag out procedure to be applied

2.4.4 Lay down Areas

Lay down areas will be defined on real time application.

2.4.5 Communication
Communication on site will be provided by radios and cellular phones (if the
Cellular phone doesn't work in all areas, radios will be preferred).

GENERAL NOTES
The purpose of this mounting guide is to describe, step by step, the process to follow in order to
realise a Wire Mesh Cable Tray installation.
All the description below refers to accessories and Cable Trays from the manufacturer's catalogue
(appendix 6) only.

Mounting requirements
Tools: Bolt cutter, Screw driver, tubular socket wrench (06mm, 08mm, 0 1Omm) & pliers
Materials: Wire Mesh Cable Tray and accessories such as couplers, rails and pendants.

Work Methodology
General notes
All Cable Trays are not the same. The technical recommendations underlined in this document refer
to only and do not under any circumstance represent other similar products or imitations.

Method Statement No: 25045-A1000-18-3GS-T-003

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Loading capacity: (see appendix 6.1)

The permissible load is indicated in the manufacturer catalogue. It corresponds to the guaranteed
load that can be supported by manufacturer. Since the load is distributed uniformly, it is expressed
in DaNlm. The standard imposes a deflection of 11100th of the span. That mash tray, being more
demanding, has reduced this figure to 11200th. For a span of 2 metres therefore, whereas the
standard requires a deflection of 20 mm, deliberately limits it to 10 mm.
Span:
th

When an 1,5 meter span, placing the splice at 115 of the span is the best solution to reach 100% of
performance.
Cutting (See picture in appendix 6.2)
In order to realise a clean cutting without any protruding parts which can be harmful for the
contractors or damage cables, it's important that the edge of the bolt cutter gets close to the
transversal wire.
When the cutting is realised with this side action bolt cutter, a layer of zinc is left behind which
means it will not be susceptible to corrosion.
Joining (See pictures in appendix 6.3)
When joining the Wire Mesh Cable Tray, the using materials are EDRN and CEFAS (Fast
Assembling System). The quantity of those accessories is depending on the widths of the Cable
Tray.
o CF541100 (Width 100)
Only 2 EDRN are required. One on each side.
o CF541200 (Width 200)
Only 2 EDRN are required. One on each side.
o CF541300 (Width 300)
2 EDRN are required. One EDRN on each side and one CEFAS on the bottom wire.
90" bends with no radius using one Cable Tray (See pictures in appendix 6.4)

When bending the Wire Mesh Cable Tray in order to make a 90" bends with radius using one Cable
Tray, the using materials are BTRCC, CE25 and ED 275. These bends are created by using one
Wire Mesh Cable Tray and by cutting part of the tray. The quantity of this accessory is depending on
the widths of the Cable Tray.
o CF541100 (Width 100)
To bend the Cable Tray, cut the longitudinal wires three times every 2 transversal wires as shown in
the picture.
o CF541200 (Width 200)

Method Statement No: 25045-A1000-18-3GS-T-003

JOINT VENTURE
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To bend the Cable Tray, cut the longitudinal wires four times (except the last 2 ones on the side)
every 2 transversal wires as shown in the picture.
o CF541300 (Width 300)
To bend the Cable Tray, cut the longitudinal wires six times (except the last 2 ones on the side)
every 2 transversal wires as shown in the picture.
90" bends with radius using one Cable Tray (See pictures in appendix 6.5)
When bending the Wire Mesh Cable Tray in order to make a 90" bends with radius using one Cable
Tray, the using materials are CEFAS (Fast Assembling System). These bends are created by using
one Wire Mesh Cable Tray and by cutting part of the tray. The quantity of this accesory is
depending on the widths of the Cable Tray.

o CF541100 (Width 100)

To bend the Cable Tray, cut the longitudinal wires twice (except the last 2 ones on the side) every 2
transversal wires as shown in the picture. 2 pieces of FASLOCK are required to join the parts of the
Wire Mesh Cable Tray.
o CF541200 (Width 200)
To bend the Cable Tray, cut the longitudinal wires four times (except the last 2 ones on the side)
every 2 transversal wires as shown in the picture. 4 pieces of FASLOCK are required to join the
parts of the Wire Mesh Cable Tray.
o CF541300 (Width 300)
To bend the Cable Tray, cut the longitudinal wires six times (except the last 2 ones on the side)
every 2 transversal wires as shown in the picture. 6 pieces of FASLOCK are required to join the
parts of the Wire Mesh Cable Tray.
T-junctions & X-junctions (See picture in appendix 6.6)
T-junctions: When creating a T-junction with Wire Mesh Cable Tray, cut the 2 longitudinal wires on
the side with a different length depending on the width of the Wire Mesh Cable Tray. The using
materials are 2 pieces of BTRCC 6x20, 2 pieces of CE30 & 2 pieces of CE30. The quantity of those
accessories is the same whatever the widths of the Cable Tray.

o CF541100 (Width 100)

Cut the longitudinal wires on the side on a length and attach by using BTRCC, CE25 and CE30 as
shown in the picture.
o CF541200 (Width 200)
Cut the longitudinal wires on the side on a length and attach by using BTRCC, CE25 and CE30 as
shown in the picture.
o CF541300 (Width 300)
Cut the longitudinal wires on the side on a length and attach by using BTRCC, CE25 and CE30 as
shown in the picture.
X-junctions: The X-junction is pretty much the same as the T-junction. Just repeat the process on
the other side to add another Cable Tray.
Level changes (See picture in appendix 6.7)

Method Statement No: 25045-A1000-18-3GS-T-003

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In order to change the level of a Wire Mesh Cable Tray, cut the 2 longitudinal wires on the side
every 2 transversal wires twice as shown in the picture. Then bend the Wire Mash Cable Tray to
realize the level change.
Support Bracket
CM 5OXXL FT0550 will be used for connecting conduits to cable tray.
Fas Roller (See picture in appendix 6.8)
Fas Roller will be used where it is necessary.
Cable Drop Accessories (See picture in appendix 6.9)
Dev100-Cablogrip will be used where it is necessary.

Hunger Support System for Cable TraylMash Tray:

Installation o f Hanger 'Threaded Rod Support
Supports: Manufacturer clevis hangers, riser clamps, threaded C-clamps with retainers,
ceiling trapeze hangers, wall bracket, and steel clamps.
a. Install individual and cable tray hangers and riser clamp to support cable trays.
Provide U bolts, clamps, attachment and other hardware necessary for hunger
assembly and for securing hanger rods and conduits.
b. Support Parallel Run of Horizontal raceway together on trapeze or bracket type
hanger.
c. Spare Capacity 25% will provide on support Size for future loads.
d. Install 8mm, 10mm and 12mm diameter or larger threaded rods.
e. In vertical runs, arrange support so the load produced by the weight of the raceway
and the enclosed conductor is carried entirely by the support, with no weight load on
raceway terminals.
f.

Cable trays shall be supported with hanger threaded rod with unistrut channel and
damp at regular intervals not exceeding 1.5 m.

g. Support cable tray directly from the building structures by using threaded rod with
expansion anchor.
Fastening of Support
a. Fasten by means of wood screw or screw type nails on wood; toggle bolts on hollow
masonry and by machine screws, welded threaded studs or spring tension clamps
steel.
b. In partition of light steel construction use sheet metal screws.

Method Statement No: 25045-A1000-18-3GS-T-003

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c. Drill holes in concrete beams so holes more than 38mm deep do not cut main
reinforcing bar.
d. Drill holes in concrete so holes more than 19mm deep do not cut main reinforcing bars.
e. Find and seal holes drilled in concrete and not used.
f.

Select fasteners so the load applied to any transfer does not exceed 25 percent of the
proof-test load.

g. Beam clamps will be used where it is necessary.

CABLE 'TRAY WARNING SIGNS
Lettering: Black letters on yellow background with legend "WARNING! NOT TO BE USED AS
WALKWAY, LADDER, OR SUPPORT FOR LADDERS OR PERSONNEL."
Labeling:
Labeling for cable tray system will be done as per in the spec 16075.

Organization, Responsibility & Supervision

Supervisor : Monitoring of the work, supervision of the application, organizing the
workforce during the installation of raceway, boxes and cabinet activities.
: Coordinates and controls the performed applications done according
Foreman
to the instructions given by the supervisor.
Workman
: Construct the defined work according to the given instructions.

Work Force
WORKFORCE
NUMBER OF PERSON

SUPERVISOR

FOREMAN
WORKMAN CLASSIFICATION

SAFETY AND HEALTH ISSUES

Method Statement No: 25045-A1000-18-3GS-T-003

WORKER

SKV OR-

3.1

Risk Assessment
Please refer to Appendix 6.8 (Risk Assessment) for the hazards and proposed control
measures.

3.2

NDIA Environmental, Safety and Health Requirements

Contractor confirms complying with the Environmental Safety and Health (ES&H)
Requirements contained in Attachment 7 of Special Conditions of Contract such as
following requirements;
ES&H orientation & Training, ES&H Pre-Task Briefings, ES&H Assessments, Incident
Notification and Investigation, Emergency Response.
In addition, Contractor shall fully comply with the following ES&H requirements:

- Safety Field Manual-25045-M-2HP-G01-009

-

Health Field Manual -25045-M-2HP-G01-020

Environmental Clearance for NDlA

- Construction Environmental Control Plan - SOJV CECP-25045-A1000-18-4CP-U-001

-SOJV -Safety Plan 25045-A1000-18-2HP-X-001
Upon the failure of contractor to comply with any of the requirements set forth in these
documents, Engineer shall have the authority to stop any operations of contractor
affected by such failure urltil the condition is remedied acceptable to the engineer

3.3

Protective & Safety Equipment

All workers engaged in the job site shall wear mandatory P.P.E in accordance to the
NDlA ESH requirements as follows;
Safety Helmet
Safety Shoes 1 Boots
Safety Glasses
High Visibility Luminous Vest
Also there will be additional special PPE to be used in case of necessary as follow;
Goggle
Dust mask
Glove
Face Shield
Additional safety protective equipment shall be issued when and as required. For
equipments, barricades should be used.

Method Statement No: 25045-A1000-18-3GS-T-003

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3.4

Contractual Requirements

SOJV ES&H PLAN

GC-19 watch in^ and Li~hting:
The Contractor shall in connection with the works provide and maintain at his own cost
all lights, guards fencing and watching when and where necessary or required by the
Engineer or by any duly constituted authority for the protection of the works or for the
safety and convenience of the public or others.
GC-31 Cooperation with other Contractors:
GC-31.1: There may be other contractors, and agents or employees of the Employer
working at or adjacent to the site during the performance of the works by the Contractor.
The contractor shall, at the Engineer's instructions and orders, allow those other
contractors who might be working for the Employer the opportunity to enable them to
execute their work. The contractor shall allow the same opportunity to the workers of the
said contractors and to the employer's workers and the government workers who might
be employed at the site or adjacent to it, to execute any work not included in this contract
or to execute any contract which might be performed by the employer and which is
related to the works of this contract, annexed to, or complementary to the works.
SC-11 Site Work Rules
1. The jobsite normal working hours are 7:00 am to 6:00 pm Sunday thru Thursday. 'The
Contractor shall obtain approval from the engineer prior to conducting site activities
outside normal working hours.
2. Contractor shall keep an up to the minute record of its employees working on site.
3. Contractor shall keep a record of all employees leaving the site at other than normal
quitting or shift change time.
4. Contractor shall take disciplinary action, including discharge, against its employees for
violations including but not limited to;
a.

Refusing to work as directed

b.

Excessive or chronic absenteeism

c.

Consumption, possession of or b e i ~ gunder the influence of drugs or alcohol

on the site.

d.

Freighting, discrimination and horseplay on site

e.

Disregard for Environmental, Health, Safety rules

Method Statement No: 25045-A1 000-18-3GS-T-003

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f.

Theft of Employer's, Engineer s or other Contractor s property

g.

Gambling on site

h.

Possession of deadly weapon(s) on site

I.

Damage, misuselor unauthorized use of permanent plant or facilities

j.

Unauthorized entry to site or site facilities

5. Contractor shall comply with all requirements of the contractors approved

Environmental, Safety and Health Programs.

6. Contractor shall provide and require all its employees to wear approved heard hats,
safety eye protection and safety working shoes and high visibility vests in any site
area designated as a Hard Required Area.
7. Contractor shall provide and require visitors to wear hard hats, safety work boots,

high visibility vest and safety eye protection in any site area designated as a hard Hat
Required Area.
8. Contractors safety representative on site shall wear green colored hard hats. The

Contractors supervisors on site shall wear yellow colored hard hats.

9. Contractors employees shall be subject to Contractor inspection of all vehicles, tool

boxes, carry boxes etc. at the site.

10. lblinors (anyone under 18 years of age) will not be permitted on site.
11. No private vehicles will be used on site, outside of designated compounds. Only
Contractors vehicles bearing Contractors logo may be used on Site.

12. Delivery Vehicles

a. All Contractors shall ensure that all delivery vehicles entering the site have some
form of paperwork, such as a delivery note collection noteloff hire note or NDlA
order, stating the purpose of the visit. It is in the interest of the Project and or
services, a correct order number, name and or location is given at the time of
ordering to ensure correct delivery of those goods, materials etc.,and all likely
losses are minimised or traced.
b. All delivery vehicle drivers must have the following Personal Protective
Equipment available for use if his delivery task requires him to work outside:
Safety Helmet
Hi Visibility Vest
Safety Boot
Safety Glasses

Method Statement No: 25045-A1 000-1 8-3GS-T-003

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c. Compliance with the above delivery requirements is the sole responsibility of the
Contractor. Failure to ensure corr~pliancewill result in stoppage of offloading.

3.5

Information to Personnel
STARRT briefina will be conducted by supervisors to all team members prior to any
activity on site. Application will be given on site for each shift /location. Supervisors will
post STARRT card adjacent to the activity location. MSDS information of the Ductile iron
epoxy repair for cement lining and adhesive lubricant used for piping system will be
transferred.

3.6

Emergency Procedures
In the event of an emergency, such as earthquake, all workers shall be evacuated and
assembled at the assigned area.
In the event of an emergency, Contractor shall follow the Emergency Procedure as
instructed by OBI (Ref: 25045-M-TSV-MAHT-18-0047 dated on 20 April 2006);&
SOJV 25045-A1000-18-2HP-X-002
1. Dial 999 and giving the location as NDlA Bechtel Construction Site. Ras Abu
Aboud Road.
2. Dial 556 5947 NDlA Emergency Response Number
3.

Dial 581 8965 Project Security to bring the emergency services to the incident
location.

All the numbers should be called only in case of emergency

In case of emergency our contact persons name and their phone number are as
follows; CP18 Interface Manager Mr.George Yousef (Ph: 5808797) and
Mr Fatih Ulu 5823799

Permit requirements
All workers shall be inducted and issued with Site Identification Badge prior to
commencement of work.
Wherever applicable, the following passeslpermits shall be applied.
Vehicle Entry Pass
Defensive Drive Permission
Permit to work
Confined Space Entry Permit (If needed)

Method Statement No: 25045-A1000-18-3GS-T-003

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ENVIROMENTAL ISSUES
4.1

Environmental Impact Assessment

In case of spilling of diesel or lubricants, necessary spill kits will be on site.

4.2

NDIA E S & H Contractor Requirements

"Exhibit B" Attachment 7 Section IV- General Environmental Management
Reauirements,
13.4: Contractor shall comply with all access restrictions, including prohibitions on access
to certain areas on or adjacent to the jobsite and require its personnel and those of
its suppliers and subcontractors of any tier comply with all signage and designations
related to such restricted areas. Restricted areas may include, but are not limited to:

i. designated wetlands;
ii. Environment mitigation study areas;
iii. cultural/historical/archaeologicalsites;
iv. designated fish, wildlife, or vegetative habitat
13.5: Contractor shall immediately stop work in any area where cultural resources or
artefacts with archaeological or historical value are discovered, and immediately
notify Employer. No artefacts, items, or materials shall be disturbed or taken from the
area of discovery. Neither contractor nor any of its suppliers and subcontractors of
any tier shall have property rights to such artefacts, items, or materials, which shall
be secured and guarded until turned over to Employer or the appropriate authorities.
Contractor shall also require that its personnel and those of its suppliers and
subcontractors of any tier comply with this provision and respect all historic and
archaeological sites in the area.
13.6: Contractor shall immediately stop works in any area where contaminated soil
indicators (such as odor or appearance), unknown containers, piping, underground
storage tanks, or similar structures are discovered, or any other materials which are
reasonably suspected to be toxic or hazardous. Contractor shall then immediately
notify employer and the stop work area shall be confirmed by employer. Activities in
the stop work area shall only resume upon Employers written approval.
13.7: Contractor shall maintain the cleanliness of all roadways when transporting fill or
spoil. Contractor shall provide appropriate facilities to ensure prompt clean up of
mud, dirt and other debris.

Method Statement No: 25045-A1000-18-3GS-T-003

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4.3

Contractual Requirements
SC-10 Dealing with Hazards and Hazardous Materials:
The employer will be responsible through a specialized contractor for the treatment,
removal or disposal of any hazardous waste or substances discovered of the works,
provided contractor shall notify Employer and Engineer as soon as practicable following
discovery.

4.4

Emergency Procedures
In case of any spilling, spill prevention programme shall be applied. House Keeping on
base of fire prevention shall be applied.

QUALITY ASSURANCE
5.1

Contractual Requirements
SOJV's QA Plan shall be followed. (Doc. No: 25045-A1000-18-GQA-001)

GC-17: The contractor shall be responsible for the true and proper setting out of the
works in relation to original points. If at any time during the progress of the Works any
error shall appear or arise in the position level dimensions or alignment of any part of the
Works the Contractor on beirlg required so to do by the Engineer shall at his own
expense rectify such error to the satisfaction of the Engineer unless such error is based
on incorrect data supplied in writing by the Engineer.

5.2

Critical Works
NIA

5.3

Inspection & Testing

ITP for Cable TraysIMash Trays Installation will be provided

5.4

Follow up & Evaluation

Daily site inspection will be carried out to ensure that work has been executed as per
approved drawings. Upon completion of installations, conduct Inspection and testing as
per ITP requirements.

Method Statement No: 25045-A1 000-1 8-3GS-T-003

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APPENDIX: Manufacturer's Catalogue (6.1-6.9)

6.10 Risk Assessment
6.1 1 Load Calculations

Method Statement No: 25045-A1000-18-3GS-T-003

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CONFIRMATION OF INSTRUCTIONS TO OPERATIVES

1 Sanyter Suniga

r-- & S I ~ I I Z - Z
i

I O ~
X KIY
&lupervisor

Any sibnificant change from this method

( statement requires it to be revised and resubmitted to OBI before work can

1

commence.

Method Statement No: 25045-A1000-18-3GS-T-003

Appendix 6.1 (lo~xlirlgcapacity chart}

Appendix 6.2 (cutting)

a Appendix 6.3 (joining)

Appendix 5.4 (90bend r-lo radius, 1 Cable Tray)

Appendix 6.5 (90' bend no radius, 1 Cable Tray)

TI . : :
- -

Appendix 6.6 (T-junction)

wd

BTRCC 6x20
CE 25
cE30

Appendix 6.7 (Level changes)

f?D

Appendix 6. 8 (Fas Roller)

Appendix 6 3 (Cable Drop Accessories)