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Method Statement 3.5 - Laying Mains (PE and Other Materials)

Document Information

Field Value
Document Reference MS 3.5
Issue Number 2
Issue Date 1 June 2026
Next Review 1 June 2027
Prepared By Sean Ashton
Approved By Aaron Mason, Director
Task No Task PPE to be worn Plant required Reference is made to the Team Pack risk assessment
3.5 Laying Mains (PE and Other Materials) As defined by on-site risk assessment Works vehicle and hand tools, mechanical excavator (depending on depth/location), pipe laying equipment N/A

Hazards

  • Manual Handling
  • Stored Energy in the Pipe
  • Defective Plant and Equipment
  • Towing Techniques
  • Incorrect Loading
  • Insufficient Space

Environmental Impacts

  • Noise
  • Dust
  • Light From Night working

Customer Impacts

  • Noise
  • Dust
  • Access

Training Required

As Per specific contract training matrix

Additional Plant and Equipment

  • Winch/Tractor Winch
  • Pipe Bursting/Slip Lining Rig
  • Mechanical Excavator

Permits Required

As Per specific contract specifications and Client requirements.

COSHH Assessment Required

  • 2 Stroke Oil
  • Diesel/Petrol
  • Line Marker Spray
  • Lubricating Spray

Sequence of Operations and Control Methods

General Requirements

  • Mains shall be laid so that they have a generally continuous, but not necessarily uniform, rise from a washout to any air valve.

  • Mains shall have a minimum cover of 900mm or a reduced depth of 800mm subject to prior agreement and generally laid to NJUG agreement or as design.

  • Any protective cap, disc or other appliance on the end of a pipe or fitting shall only be removed permanently when the pipe or fitting which it protects is about to be jointed. Any exposed pipe ends shall be capped when the pipe laying is not actively being carried out to prevent vermin or soil entering the pipe work.

  • Suitable measures shall be taken to prevent extraneous material from entering pipes and to anchor each pipe to prevent flotation or other movement before the works are complete.

  • A welded PE Dome Cap End shall be fitted to the pipe end when inserting under services or other obstructions in an open cut trench. The dome end shall be removed directly before connecting the pipe at the relevant tie-in points.

  • Pipes and fittings, including any lining or sheathing, shall be examined for damage before laying. Plastic pipes shall be carefully examined for flaws; particular watch shall be kept for signs of impact damage or scoring. No polyethylene pipe shall be installed with scores or cuts penetrating more than 10% of the wall section. If, after installation, scores or cuts penetrating more than 10% of the wall section are found, the affected lengths of pipe shall be removed.

  • Pipes, valves and fittings shall be thoroughly cleaned immediately before lowering into the trench. Each pipe shall be examined for dirt, which if present, shall be removed with a brush.

  • Where marker tape is specified, it shall be laid between 100mm and 300mm above the pipe.

  • Where a tracer system is specified, it shall be continuous and adequately secured to valves and fittings.

  • Where a marker tape containing a wire is used, joins in the tape shall be securely made and continuity of tracer shall be ensured. Ends of the wire shall be exposed within the chamber just below the cover level.

  • Pipes on private property that may be subject to normal roadway loadings (e.g. factories, hospitals) they should be laid with a depth of cover as roads.

If squeezing-off of Polyethylene pipe is permitted then the following shall be required:

  • Limited to pipe up to and including 180mm O.D.

  • Only purpose-made equipment shall be used with the stops correctly set for the pipe diameter and wall thickness to avoid over-compression of the pipe

  • Not to be used within 5 pipe diameters of a permanent fitting or fusion joint or previous squeeze-off.

  • Pipe shall be inspected on release of a squeeze-off and any section showing cracking or splitting shall be cut out and replaced.

  • Pipe 90 to 180 mm OD, which forms part of the permanent work, shall be fitted with a stainless steel band clamp over the squeeze-off

  • Pipe less than 90mm OD shall be clearly and indelibly marked where the squeeze-off has occurred

Pipe Installation

Pipe installed by the Developer shall be adequately supported and restrained to resist a pressure compatible with the test pressure of the pipe.

Where pipes with flexible joints need to be laid in curves, the deflection at any joint shall not exceed ¾ of the maximum deflection recommended by the manufacturer.

Flanges shall be properly aligned before any bolts are tightened. Bolt threads shall be treated with graphite paste and the nuts tightened evenly in diametrically opposite pairs. The use of flange adaptors and couplings shall be kept to a minimum when installing branches and bends in connection with hydrants and valves.

Removing the banding from the coils:

  • Take care when unloading coils to ensure all banding is undamaged
  • Do not remove bands until the material is required for use.
  • When the bands are to be released, cut the band securing the outer end of the coil first, followed by bands securing successive layers only removing sufficient bands to release the length of pipe, which is required immediately.
  • Use coil trailers as appropriate to pipe size and risk assessment.

Observe the following precautions when storing pipes:

  • Store on firm level ground
  • Use wedges to prevent movement
  • Do not store individual straight pipes of up to 125 mm diameter more than eight pipes high
  • Do not store individual straight pipes over 125 mm diameter more than four pipes high
  • Do not store pipes in packs more than two packs high
  • Do not store individual coils more than two coils high
  • Clean pipe sticks with a pull through before laying and jointing.

Thrust blocks

Appropriate thrust blocks shall be installed in accordance with the Construction drawings.

Saddle Fusion (using strap type loading tool)

  • Remove fitting from Bag and place on main where to be welded. Mark out around the tee using felt tip pen.
  • Remove the fitting and keep it clean, scrape the pipe to remove the surface layer only.
  • Remove the threaded cap from the tee and check cutter head is flush with the fitting.
  • Place the fitting on top of the prepared area on the main pipe.
  • Press the nose of the loading tool into the aperture in the top of the tapping tee cutter and push fully home.
  • Holding the loading tool and fitting in one hand, push the straps under the main and up through the slots of the tool. Clamp the fitting in place by tightening the straps.
  • Set up and connect the electro fusion box to the terminals of the fitting and fuse tee as per manufacturers timing and allow it to cool as per manufacturer's time.
  • After 30 mins of the cooling cycle remove clamp and set up tapping Key.
  • Drill the tee in a clockwise direction until the pipe wall is completely cut through.
  • Retract the Tapping Key in an anti-clockwise direction until the cutter is flush with the top of the threaded stack.
  • Check that there is an "O"-Ring in the threaded cap and screw the cap tight onto the tee.

If using a Pedestal type stacking tool:

  • Release the wing nut on the pedestal and press the nose of the loading tool into the cutter head.
  • Place the grooved base plate underneath the pipe, lower the tapping tee onto the scraped area, and tighten the wing nut.
  • Screw the hand wheel of the top-loading tool to clamp the tool.
  • Reverse (3) to remove the top-loading tool.

Saddles used on Protecta-Line pipe require wrapping with foil to maintain protection from ground conditions.

The laying of service pipe shall be as for mains generally including requirements for use of Protecta-Line. Diagram above indicates depth requirements and setting out arrangements where this is not specified by the designer.

Dealing with Water

  • Excess water shall not be allowed to lie on the works. Water shall be disposed of to an approved location. Drainage sumps shall be sited, as far as practicable, outside the area excavated for the works and re-filled with approved material to the required level.
  • All necessary precautions shall be taken to prevent any adjacent ground from being adversely affected by loss of fines through any de-watering process.
  • All necessary precautions shall be taken to prevent any ground water from entering mains.
  • Where water is to be discharged across road and footpath surfaces and the temperature is likely to fall to freezing point then no pumping shall be undertaken and refer to your Supervisor.

Laying of Mains in other materials - Ductile Iron

  • Ensure the pipes are offloaded and stored in accordance with the manufacturer's recommendations.
  • Check that the design refers to the specification BS EN 545 and ensure the delivery note from the Supplier records the specification.
  • Ensure the tubular protective coating is not damaged upon delivery, at storage, and prior to installation.
  • Place the Pipe on a bedding material approved by the Designer
  • Tape the joints in the tubular sleeve to form a continuous barrier over the pipe
  • Place fine fill around the pipe as approved by the Designer

UPVC Pipes and Fittings

  • Ensure the pipes are offloaded and stored in accordance with the manufacturers recommendations.
  • Lay the Pipe on an approved bed as specified by the Designer and the manufacturer.
  • Join the pipe in accordance with manufacturer's specification noting push-fit joints shall be spigot and socket.
  • Place fine fill around the pipe as approved by the Designer.

Protecta-Line Pipe and fittings

[Content continues as per manufacturer specifications]