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RAPID P0014 0008 CON MST 0001 0109

PETRONAS RAPID PROJECT

PACKAGE 14- UTILITIES, INTERCONNECTING,
OFFSITE UNITS

1 - REJECTED

Do not proceed with any work defined by the data

submitted. Revise and resubmit per Purchaser
comments consistent with the Purchase Order,
unless otherwise noted.

Authorization to proceed does not relieve Contractor

/Supplier of its responsibility or liability under the
METHOD STATEMENT Contract and/or Purchase Order.

FOR

WATERPROOFING AND EXPANSION JOINT

3 - PROCEED
Authorization to proceed does not relieve Contractor
/Supplier of its responsibility or liability under the
Contract and/or Purchase Order.

OWNER Approval : PRPC Utilities and Facilities Sdn. Bhd.

Name : By Lau Lee Yeng on May 26, 2017
Date (DD-MMM-YY) :

Signature :

Document Class : Z

Pages modified under this revision: -

Ervina mohd fazil Ihsan

cn=Ihsan, o, ou,
2017.05.22 email=ihsan_idris@

11:48:52
2017.05.22 wct.my, c=MY
2017.05.22 11:49:18

+08'00'
11:56:48 +08'00'
+08'00'

1 22-May-17 IFC – Issued for Construction Ervina@Zurinah Mutih Mohd Fazil Mohd Noh Ihsan Idris

0 19-Apr-17 IFC – Issued for Construction Siti Rodhiana Mohd Fazil Mohd Noh Ihsan Idris

B 4- Mar-17 IFA-Issued for Approval Nur Najihah Wahab Mohd Fazil Mohd Noh Ihsan Idris

A 2-Feb-17 IFR – Issued for Review Nur Najihah Wahab Mohd Fazil Mohd Noh Ihsan Idris

DATE WRITTEN BY
CHECKED BY
APPROVED BY
REV.
STATUS – REVISION MEMO
DD-MMM-YY (name & signature) (name & signature)
(name & signature)

"In accordance with Article 41 of the Conditions of Contract, the ownership in this document shall vest in OWNER. No part of this document may be reproduced, stored in a retrieval
system or transmitted in any form or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the OWNER.
CONFIDENTIAL – Not to disclose without authorization”

Electronic Filename: RAPID-P0014-0008-CON-MST-0001-0109_0.doc

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RAPID P0014 0008 CON MST 0001 0109

METHOD STATEMENT FOR WATER PROOFING AND

EXPANSION JOINT WORK

CONTENTS

1. Introduction……..……………………………………………………………………….3
2. Acronym and Definition………………………………………………………………..4

3. Objective and Scope of Work…………………………………………………………4

4. References……………………………………………………………………………….4

5. Resources Planning…………………………………………………………………….4

5.1 Material Planning………………………………………………………………….....5

5.2 Machinery and Equipment Planning……………………………………………….5

5.3 Manpower Planning………………………………………………………………….5

6. Construction Procedures……………………………………………………………...5

6.1 Preliminary Procedures……………………………………………………………...5

6.2 Scaffolding and Work at Height…………………………………………………….6
6.3 Material and Proper Storage ………………….…………………………………...6

6.4 Work Procedure……………………………………………………………………..7

7. QAQC Aspect……………………………………………………………………….….14

8. Safety and Health Aspects……………………………………………………….….15

"In accordance with Article 41 of the Conditions of Contract, the ownership in this document shall vest in OWNER. No part of this document may be reproduced, stored in a retrieval
system or transmitted in any form or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the OWNER.
CONFIDENTIAL – Not to disclose without authorization”

Electronic Filename: RAPID-P0014-0008-CON-MST-0001-0109_1.doc

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METHOD STATEMENT FOR WATER PROOFING AND

EXPANSION JOINT WORK

1. INTRODUCTION

PETRONAS intends to build a grass root integrated Refinery and Petrochemicals

Complex by developing the RAPID PROJECT (Refinery and Petrochemical

Integrated Development) to meet both domestic and Asia's energy and chemicals

demand. The RAPID PROJECT consists of a world scale integrated site which

includes Refinery with a deep conversion scheme, 300 000 barrels per stream day

capacity, Naphtha Steam Cracker of 1.28 million tons of ethylene per year capacity;

Petrochemical Derivative Units, utilities, off site and jetty installations.

The RAPID PROJECT is a fundamental component of the Pengerang Integrated

Complex (PIC) which also includes the following major projects; Pengerang

Cogeneration Plant (PCP), a new LNG Regasification Terminal (RGT2), Raw

Water Supply Project (PAMER), Pengerang Deep Water Terminal (PDWT) and Air

Separation Unit (ASU) which provides oxygen and nitrogen gases to the Complex

and to the local market. The RAPID PROJECT is located at Pengerang, Mukim of

Pengerang, Kota Tinggi District, Johor and is in close proximity to the international

shipping lane connecting the Straits of Malacca, Singapore and the South China

Sea.

WCT has been contracted by PRPC Package 14-1702 of RAPID complex. The

Package 14-1702 is an EPCC contract providing Engineering, Procurement,

Construction & Commissioning (EPCC) of Substations (275kV, 33kV & 11kV),

Field Auxiliary Rooms, Operator Shelter Buildings and Local Control Building. This

method statement introduces construction methodology of water proofing, and

expansion joint work.

"In accordance with Article 41 of the Conditions of Contract, the ownership in this document shall vest in OWNER. No part of this document may be reproduced, stored in a retrieval
system or transmitted in any form or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the OWNER.
CONFIDENTIAL – Not to disclose without authorization”

Electronic Filename: RAPID-P0014-0008-CON-MST-0001-0109_1.doc

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METHOD STATEMENT FOR WATER PROOFING AND

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2. ACRONYMS AND DEFINITIONS

OWNER PRPC Utilities and Facilities Sdn. Bhd.

EPCM CONTRACTOR OUI JV: Joint venture appointed by OWNER

with specified authority to perform the EPCM

Services of UIO Project.

PROJECT or UIO PROJECT EPCM of utilities, interconnecting and offsite

facilities (UIO) Package 14 for RAPID

PROJECT at Pengerang, Johor.

EPCM Engineering, Procurement and Construction

Management
PACKAGE means each package of works or supplies

forming part or parts of the PROJECT.

PACKAGE CONTRACTOR means any Contractor engaged by OWNER to

undertake the PACKAGE WORKS for a

PACKAGE
SUBCONTRACTOR means any company which EPCM

CONTRACTOR has engaged or proposes to

engage (s the context may require) to undertake

any part of the EPCM CONTRACTOR Services

3. OBJECTIVE & SCOPE OF WORK

x To outline the sequence of work for Water Proofing and Expansion Joint Work.

The extent of work shall be in accordance with the contract documents inclusive

the established specification and drawing.

x To outline details step by step construction methodology until completion of the

work.
x To outline preparation or coordination required before start work
x To outline quality plan or inspection test required during project implementation
x To perform safe working environment and compliance to the safety requirements.

"In accordance with Article 41 of the Conditions of Contract, the ownership in this document shall vest in OWNER. No part of this document may be reproduced, stored in a retrieval
system or transmitted in any form or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the OWNER.
CONFIDENTIAL – Not to disclose without authorization”

Electronic Filename: RAPID-P0014-0008-CON-MST-0001-0109_1.doc

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4. REFERENCE

Reference Description

1. RAPID-P0014-OUI-ARC-DES-0001- Project Specification: Building and

0001_0 Architectural Specification

5. RESOURCES PLANNING

5.1 Material Planning

Item Material Descriptions

1. Polyurethane Waterproofing Membrane - XYLASTIC-500

2. Cementitious Waterproofing Coating - XYLASTIC-FLEXCEM

3. Extruded Polystyrene Thermal Insulation Board - SEALFLEX XPS

4. Liquid Rubber Membrane - TRITOFLEX

5. Heavy Duty Fiber Mesh

5.2 Machinery & Equipment Planning

Item Machinery & Equipment Descriptions

1. Light Steel Trowel

2. Electric Stirrer

3. Squeegee

4. Roller

5. Brush/Broom

6. Airless Spray Equipment

7. Glove

"In accordance with Article 41 of the Conditions of Contract, the ownership in this document shall vest in OWNER. No part of this document may be reproduced, stored in a retrieval
system or transmitted in any form or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the OWNER.
CONFIDENTIAL – Not to disclose without authorization”

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METHOD STATEMENT FOR WATER PROOFING AND

EXPANSION JOINT WORK

5.3 Manpower Planning

Item Manpower Descriptions

1 Project Manager
2 Site Quality Manager

3 QAQC Engineer
4 QC Inspector
5 Site Supervisor / Coordinator
6 Safety Supervisor

7 Skill Workers-Water Proofing Application

8 General Workers

6. CONSTRUCTION PROCEDURE

6.1. PRELIMINARY PREPARATION

6.1.1 Submit for approval and ensure shop drawings have been approved.

6.1.2 Submit for approval and ensure materials have been approved.

6.1.3 Submit and ensure Method Statement, Inspection and Test Plan to

the Engineer have been approved.

6.1.4 Arrange all necessary personnel, equipment and services are

required for the works and ensure adequate water, lighting, power and

access arrangement are in place.

6.2. SCAFFOLDING AND WORK AT HEIGHT

Please refer to PERI Scaffolding Installation

6.3. MATERIALS AND PROPER STORAGE

System and procedure of preservation, delivery and storage of materials

shall be in accordance to established Procedure & Inspection Test Plan

(ITP).
"In accordance with Article 41 of the Conditions of Contract, the ownership in this document shall vest in OWNER. No part of this document may be reproduced, stored in a retrieval
system or transmitted in any form or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the OWNER.
CONFIDENTIAL – Not to disclose without authorization”

Electronic Filename: RAPID-P0014-0008-CON-MST-0001-0109_1.doc

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METHOD STATEMENT FOR WATER PROOFING AND

EXPANSION JOINT WORK

6.4. WORK PROCEDURE

6.4.1 RC FLAT ROOF WATERPROOFING APPLICATION

6.4.1.1 SURFACE PREPARATION

x Ensure the structure in such condition that apart from final cleaning, it

will be ready to receive the waterproofing system.

x All the timber formwork, steel bar, construction debris, concrete

dropping, paints, solvents, oils, grease or like materials and loose

debris, including mud etc to be removed from the structure.

x All cracks honeycomb or defective structure shall be repaired prior

application of waterproofing system.

x All penetrations including piping systems and through-concrete

structures, etc are to be properly and permanently positioned.

x The concrete surface shall be smooth and clean. Any sharp projections

shall be removed.

6.4.1.2 APPLICATION METHOD

Waterproofing Coating

x All surface to be swept clean.

x Prior to application, stir well XYLASTIC-500 in order to achieve a

homogeneous mixture. Let is settle in order to let entrapped air escape.

x XYLASTIC-500 may be applied by broom, roller, trowel, and squeegee

or by airless spray equipment.

"In accordance with Article 41 of the Conditions of Contract, the ownership in this document shall vest in OWNER. No part of this document may be reproduced, stored in a retrieval
system or transmitted in any form or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the OWNER.
CONFIDENTIAL – Not to disclose without authorization”

Electronic Filename: RAPID-P0014-0008-CON-MST-0001-0109_1.doc

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METHOD STATEMENT FOR WATER PROOFING AND

EXPANSION JOINT WORK

x Dilute one part XYLASTIC-500 to one part water and apply first or

2
0.30kg/m .

x When the first coat still wet or tacky, lay one layer of heavy duty fiber

mesh reinforcement onto the first coat.

2
x Apply second coat XYLASTIC-500 or 0.50kg/m and allow curing.
2
x Apply third coat XYLASTIC-500 or 0.50kg/m and allow curing.

x For flood testing, the newly applied XYLASTIC-500 coating must be

cured for at least 24 hours beforehand. Plug off all outlets, down pipes

and etc. Then flood with min 25mm of water and leave for 24 hours prior

inspection. Where it is impracticable, because or slab screed to falls or

otherwise to contain the 25mm depth of water, the slab shall be induced

with water by continuously sprinkle with water for 4 hours.

Laying Topping Concrete with Panel Joints

x Lay one layer of 50mm thick extruded thermal insulation board in

interlocking system which interlocks with the key provided on the

material.

x Lay one layer 0.25mm thick polythene sheet on top of insulation board.

x Form level peg and position on R.C flat roof surface.

x Place one layer of steel reinforcement mesh BRC A5.

x Place average 65mm thick concrete topping to fall and steel trowel to

require finish level.

x Place average 65mm thick concrete topping to fall and steel trowel to

require finish level.

x Upon concrete fully cured, mark in line to demarcate 3 meter x 3 meter

panel and diamond cut 12mm wide x 8mm deep groove line.

"In accordance with Article 41 of the Conditions of Contract, the ownership in this document shall vest in OWNER. No part of this document may be reproduced, stored in a retrieval
system or transmitted in any form or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the OWNER.
CONFIDENTIAL – Not to disclose without authorization”

Electronic Filename: RAPID-P0014-0008-CON-MST-0001-0109_1.doc

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METHOD STATEMENT FOR WATER PROOFING AND

EXPANSION JOINT WORK

x Clean groove line and sealed joint by using UV resistant polyurethane

sealant.

WATERPROOFING DETAIL RC FLAT ROOF

6.4.2 TOILET WATERPROOFING APPLICATION

6.4.2.1 SURFACE PREPARATION

x Ensure the structure in such condition that apart from final cleaning, it

will be ready to receive the waterproofing system.

x All the timber formwork, steel bar, construction debris, concrete

dropping, paints, solvents, oils, grease or like materials and loose

debris, including mud etc to be removed from the structure.

x All cracks honeycomb or defective structure shall be repaired prior

application of waterproofing system.

"In accordance with Article 41 of the Conditions of Contract, the ownership in this document shall vest in OWNER. No part of this document may be reproduced, stored in a retrieval
system or transmitted in any form or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the OWNER.
CONFIDENTIAL – Not to disclose without authorization”

Electronic Filename: RAPID-P0014-0008-CON-MST-0001-0109_1.doc

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METHOD STATEMENT FOR WATER PROOFING AND

EXPANSION JOINT WORK

x All penetrations including piping systems and through-concrete

structures, etc are to be properly and permanently positioned.

x The concrete surface shall be smooth and clean. Any sharp projections

shall be removed.

6.4.2.2 APPLICATION METHOD

x All surface to be swept clean.

x Prior to application, stir well XYLASTIC-FLEXCEM in order to achieve a

homogeneous mixture. Let is settle in order to let entrapped air escape.

x XYLASTIC-FLEXCEM may be applied by broom, roller, trowel, and

squeegee or by airless spray equipment.

x Supply and apply two coats of XYLASTIC-FLEXCEM cementitious

2
Flexible waterproofing membrane or 1.0kg/m per coat onto proper

prepared concrete surface, all in accordance with manufacturer’s

instruction.

x Supply and apply two coats of XYLASTIC-500 liquid applied seamless

2
modified polyurethane waterproofing membrane at the rate of 0.5kg/m

Per coat onto proper prepared concrete surface, all in accordance with

manufacturer’s instruction.

"In accordance with Article 41 of the Conditions of Contract, the ownership in this document shall vest in OWNER. No part of this document may be reproduced, stored in a retrieval
system or transmitted in any form or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the OWNER.
CONFIDENTIAL – Not to disclose without authorization”

Electronic Filename: RAPID-P0014-0008-CON-MST-0001-0109_1.doc

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METHOD STATEMENT FOR WATER PROOFING AND

EXPANSION JOINT WORK

WATERPROOFING DETAIL FOR TOILET

6.4.3 EXPANSION JOINT

The expansion joint will be 2 options as below:-

Option 1 – Expansion joint with gap 25~50mm

Option 2 – Expansion joint with gap >50mm

6.4.3.1 SURFACE PREPARATION

Surface preparations for both options are same. All surface must be

pressure washed clean, free of loose materials, grease, oils, release

agents, and other contaminants. Any damaged areas and existing

substrate should be properly patched or sealed with appropriate repair

materials that will bond to the existing substrates and will allow TRITOflex

to bond well to it. TRITOprime is used for asphaltic based substrates as

"In accordance with Article 41 of the Conditions of Contract, the ownership in this document shall vest in OWNER. No part of this document may be reproduced, stored in a retrieval
system or transmitted in any form or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the OWNER.
CONFIDENTIAL – Not to disclose without authorization”

Electronic Filename: RAPID-P0014-0008-CON-MST-0001-0109_1.doc

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METHOD STATEMENT FOR WATER PROOFING AND

EXPANSION JOINT WORK

well as for concrete and metal to create a superior bond with the

TRITOflex membrane.

6.4.3.2 APPLICATION METHOD

Option 1

Application methods for external, internal and external wall in option 1 are

same. Supply and spray apply one layer of 1.5mm thick TRITOflex instant

setting liquid rubber membrane with 1914% elongation onto proper

prepared surface. All in accordance to manufacturer’s instruction.

DETAIL FOR EXPANSION JOINT AT EXPOSED WALL

"In accordance with Article 41 of the Conditions of Contract, the ownership in this document shall vest in OWNER. No part of this document may be reproduced, stored in a retrieval
system or transmitted in any form or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the OWNER.
CONFIDENTIAL – Not to disclose without authorization”

Electronic Filename: RAPID-P0014-0008-CON-MST-0001-0109_1.doc

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METHOD STATEMENT FOR WATER PROOFING AND

EXPANSION JOINT WORK

DETAIL FOR EXPANSION JOINT AT EXPOSED ROOF

DETAIL FOR EXPANSION JOINT (INTERNAL)

"In accordance with Article 41 of the Conditions of Contract, the ownership in this document shall vest in OWNER. No part of this document may be reproduced, stored in a retrieval
system or transmitted in any form or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the OWNER.
CONFIDENTIAL – Not to disclose without authorization”

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METHOD STATEMENT FOR WATER PROOFING AND

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Option 2

Application methods for external, internal and external wall in option 2 are

same. Supply and spray apply one layer of 2.0mm thick TRITOflex instant

setting liquid rubber membrane with 1914% elongation onto proper

prepared surface. All in accordance to manufacturer’s instruction. 6mm

thick removable MS plate installed on top, bolted with 12mm countersunk

bolt.

DETAIL FOR EXPANSION JOINT AT EXPOSED WALL

"In accordance with Article 41 of the Conditions of Contract, the ownership in this document shall vest in OWNER. No part of this document may be reproduced, stored in a retrieval
system or transmitted in any form or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the OWNER.
CONFIDENTIAL – Not to disclose without authorization”

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METHOD STATEMENT FOR WATER PROOFING AND

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DETAIL FOR EXPANSION JOINT AT EXPOSED ROOF

DETAIL FOR EXPANSION JOINT (INTERNAL)

"In accordance with Article 41 of the Conditions of Contract, the ownership in this document shall vest in OWNER. No part of this document may be reproduced, stored in a retrieval
system or transmitted in any form or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the OWNER.
CONFIDENTIAL – Not to disclose without authorization”

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7. QAQC ASPECT

7.1 The purpose of the quality control is to provide a guideline for a proper

operation framework such that the following targets will be attained: -

o To achieve consistently high quality standards of workmanship in all

aspects of the work.

o All quality matters shall follows as per MS ISO 9001 : 2000 and Project

Quality Plan to ensure the quality in construction.

7.2 Issuance of Request for Inspection

Any work in which to be carried out at site shall be requested by formal

requisition as stated in established procedure by using RFIN format form

and implemented according to Request for Inspection Procedure

referenced RAPID-P0014-OUI-CON-PRC-0001-2006_0

8. SAFETY, HEALTH AND ENVIRONMENTAL ASPECTS

x Safety and health aspects at site shall adhere strictly to the requirements

set by DOSH/ NIOSH and DOE.

x All machinery and equipment are to be checked at the site to ensure that it

is well functioning and be handled by only trained personnel with relevant

experience.

x Material Safety Data Sheet (MSDS) shall be prepared and always be

available at site.

x Sufficient care shall be exercise in handling and slinging of materials.

x Material is to be fastened in such way to prevent slipping (multiple loop grip

tie) with the following controls :-

o No dragging along ground.

"In accordance with Article 41 of the Conditions of Contract, the ownership in this document shall vest in OWNER. No part of this document may be reproduced, stored in a retrieval
system or transmitted in any form or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the OWNER.
CONFIDENTIAL – Not to disclose without authorization”

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o Lifting rate at slower pace.

x All supervisor and workers are to use PPE safety requirements at site area

at all time. Where site condition is damp and wet the use of rubber boots in

which has been reinforced by steel not only in the toes but also in the soles

is essential.

x All soft spots or holes shall be identified and barricaded if necessary.

x The site shall be kept clean and clear of unnecessary obstruction. First aid

boxes in the charge of a responsible person have to be kept on all working

areas.

x Appropriate and sufficient safety signboards, barriers and lighting shall be

provided as necessary by the nature of and location of the works. Safety

and health plan for the project site shall be conducted to achieve a secure

working environment.

x While working at height:

o 100% tie off while working at roof by using proper anchor point

(lifeline)

o Make sure workers properly hydrated by drinking water frequently.

o Always carry only needed tools while performing work on top of

roof.

o To ensure workers to attend Working at Height Training under OUI

JV.

o PTW should be applied and approved complete with working at

height and working on roof permit.

o STA must be conducted prior starting work

o All workers must attend OUI JV’s working at height training

"In accordance with Article 41 of the Conditions of Contract, the ownership in this document shall vest in OWNER. No part of this document may be reproduced, stored in a retrieval
system or transmitted in any form or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the OWNER.
CONFIDENTIAL – Not to disclose without authorization”

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METHOD STATEMENT FOR WATER PROOFING AND

EXPANSION JOINT WORK

x While working on scaffolding:

o Scaffolding must be erected and dismantled by Qualified Scaffolder.

o Scaffold fittings and other connections should be securely tightened.

o All bracings, ties, guys and buttresses should be installed as the

scaffold is erected.

o Adequate anchor points with life lines shall be provided for workers

to hook when performing roof work.

o Do not climb on guardrails to gain extra height

o Edge protection and any means of access can be removed as the

scaffolding is dismantled provided it is removed at the last possible

stage.

o To prevent injury, do not drop scaffolding components from height

during dismantling.

o Wear full body harness and hook up to suitable anchor point.

o Barricade and display warning signage at scaffolding work area while

erection and dismantling

o No other activity below while work being perform

o Scaffolding Tag must be installed (Red / Green)

"In accordance with Article 41 of the Conditions of Contract, the ownership in this document shall vest in OWNER. No part of this document may be reproduced, stored in a retrieval
system or transmitted in any form or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the OWNER.
CONFIDENTIAL – Not to disclose without authorization”

Electronic Filename: RAPID-P0014-0008-CON-MST-0001-0109_1.doc