Method Statement for Installation of Cable Trays, Ladders, and Trunking System

1. Purpose

What is the Method Statement for Installation of Cable Trays, Ladders, and Trunking System?

This Method Statement formalizes the requirements for the Installation of Cable Trays, Ladders, and Trunking Systems. The specifications, procedures, and guidelines contained in this Method Statement specify the technical requirements to be followed and also act as a reference to clearly establish defined standards for work assessment.

Moreover, this document shall provide guidelines to check that specified materials are installed and agreed procedures are implemented during the execution of work and to define the responsibilities for controlling the execution.

 2. Scope

The scope of this Method Statement is to describe the sequence of activities involved in the Installation of Cable Trays, Ladders, and Trunking Systems as per the requirements of contract specifications, and codes, standards of the project titled under: “Name of the Project Here”

3. System Description

For effective Cable Management at the project site, cable Ladders, cable trays, and trunking systems are applicable to meet the load requirements. These shall be used for all types of HV/LV/MV/ELV cables containment including but not limited to main cables routed to branch cables for main circuits, LV cabling inside Tunnel, Cables routed to carpark, buildings, substations, control, and power cables, fire detection, and alarm system, 415V switchgear, switchgear, and control gear, panels, all distribution boards, public address system, etc.

4. Definitions

Supplier/Vendor – Seller of material as defined in the project specification
Must – Signifies a legal or statutory requirement
Shall – Signifies a requirement made mandatory by this specification
May – Signifies a feature, which is discretionary in the context in which it is applied.
Will – Signifies feature that the supplier may assume to be already present

5. References

Project Electrical Specification
BS EN 61537 Cable tray system and cable ladder system for cable management
Approved material submittals
Approved shop drawings

6. Abbreviations

HSE Health Safety and Environment
QA/QC Quality Assurance and Quality Control
MST Method Statement
RSK Risk Assessment
ITP Inspection and Test Plan
PQP Project Quality Plan
INR Inspection Request
PPE Personnel Protective Equipment
MEP Mechanical, Electrical & Plumbing
STARRT Safety Task Analysis Risk Reduction Talk

7. Responsibilities

A. General

1. Project Manager (MEP) will be responsible to manage, execute, complete, and handover the construction activities within approved budgets and resources in compliance with Project Requirements as specified in Project Specifications. He will be overall in charge of implementing the Method Statement in accordance with QA/QC and HSE requirements.

2. Construction Manager will be responsible for managing construction activities and will lead and communicate with site Supervision, Subcontractors, and Vendors to assist them in working to the Project Schedule by conforming to QA/QC and HSE requirements at the site.

3. HSE Manager will be responsible for planning, coordinating, and implementing issues and directives within the organization. He ensures safe environmental working conditions for all employees.

4. QA/QC Manager will be responsible for supporting the project team in implementing and maintaining Quality Management System for the project through PQP, ITP, MST, and Procedures in compliance with Project specifications, Codes, and Standards.

5. HSE Officer will ensure the enforcement of safety procedures in accordance with the approved HSE Plan. Will be closely monitoring the site engineer’s strict implementation of the MS and Risk Assessment, the use of proper tools and equipment to maintain safety, certifications of equipment and their adherence to safety regulations, reporting of any unsafe work, or stopping work that does not comply with HSE procedures.

6. Site Engineer will be responsible for carrying out all construction-related activities with compliance to HSE and QAQC requirements as per contract specifications, drawings /documents, codes, and standards.

7. QA/QC Engineer will be responsible for conducting inspections as per PQP.

8. Supervisor/Foreman will be responsible for coordinating all works and workers related to the job.

9. Electrician / other tradesmen will be responsible for assisting his superiors during all construction work-related activities following HSE and QAQC requirements.

10. Store In-charge receives and inspects all incoming materials and reconciles them with documents; processes and distributes documentation; reports, documents, and tracks damages and discrepancies.

11. The security guards will be clearly visible, and vigilant, respond quickly and correctly during the crisis, observe and report, check and monitor, maintain order among workers, and offer safety warnings and tips.

B. Organization Chart

C. Interfacing with other Operations

Other Mechanical, Electrical, and Plumbing works and Architectural, Civil, and Structural Requirements

D. Duration, Phasing with the Subcontractors

All works associated with construction work referred to in this Method Statement shall be completed as per the project schedule.

E. List of Subcontractors

Main Contractor: xxxxxx
Subcontractors for MEP: xxxxxx

F. Handling and Storage

F.1 Workmanship

1. All plants and equipment shall be stored off the ground under a weatherproof cover ready for incorporation in the works. All electrical apparatus shall be examined and cleaned before installation. All open conduit ends shall be fitted with plastic caps or suitable protective covering to prevent the ingress of foreign matter. All drums with cables shall be protected from direct sunlight.

2. The lay-down area shall be arranged for offloading the materials prior to transport at the site.

3. The storage area shall be cleaned and is at a minimum height of 1 ft from the ground level. The materials shall be stored in a shaded area to protect them from exposure to direct sunlight/rain etc. Separate areas in the storage zone must be marked for different materials.

4. Slings used to lift the materials must be checked for damages and defects. Slings shall not be shortened with knots and bolts or other makeshift devices. Slings should not be kinked and should not be loaded in excess of their safe working load. Slings shall be padded or protected from the sharp edges of their load.

5. All employees shall be kept clear of the load about to be lifted and of the suspended load. Hands and fingers shall not be placed between the slings and their load while the sling is being tightened around the load. Slings shall not be pulled from under a load when the load is resting on the sling. Always use two-point loading to avoid load slipping.

6. Forklift / Crane must be third-party certified and fit for the purpose. Ensure that operator must be qualified, trained, and with a valid license. Ensure daily inspection of forklifts has been carried out prior to commencement of work.

7. All plants and equipment shall be stored off the ground under a weatherproof cover ready for incorporation in the works. All electrical apparatus shall be examined and cleaned before installation. All open conduit ends shall be fitted with plastic caps or suitable protective covering to prevent the ingress of foreign matter. All drums with cables shall be protected from direct sunlight.

F.2 Specific Requirements

The Site Store In-charge/Storekeeper shall ensure the following in particular:

1. Straight lengths of trays, ladders, covers, and channel

It is recommended that where possible non-metallic banding is used in order to avoid rust stains forming on galvanized products and contamination of stainless steel products. Where products of five-meter length or above are packed in bundles, they shall be supported with a sufficient number of timber bearers that provide sufficient clearance to accommodate the forks of a forklift. Bundles should be placed on a flat-level surface with timber bearers. If the bundles are stacked on top of one another they should be aligned vertically.

2. Boxed and bagged parts

Boxes and bags should be stacked onto suitably sized pallets for handling by a forklift. Pallets of parts must be kept dry and stacking should be avoided.

3. Tray and Ladder Fittings

Small parts should be stacked onto suitable-sized pallets for handling by a forklift. Each pallet should be suitably wrapped in order to secure the parts. Pallets of parts must be kept dry and stacking should be avoided. Large parts should be packed and transported in the same way as the straight lengths detailed above.

4. Storage

Products that are either Hot dipped Galvanized after manufacture, stainless steel, or nonmetallic can be stored outside without cover (excluding boxed items). When stored outside products should be stacked in a method that ensures adequate drainage.

However outside storage is not recommended for galvanized products due to ‘wet storage stain’ galvanized products if exposed to become wet while stacking awaiting transportation/installation, the finish may quickly suffer from unsightly staining and powder on the surface. This is known as a ‘wet storage stain’.

Ideally, the metallic products should be stored undercover in a dry, unheated environment and be loosely stacked off the ground to ensure adequate ventilation. All products should be stored away from areas where processes or activities could cause damage or contamination.

F.3 Responsibilities

1. The Store In-charge shall ensure that all approved supplies be delivered to the site as per the approved material submittal with the manufacturer’s seals, labels, or other proof of origin intact. These labels and seals shall not be removed until the material is required for use and shall be retained for inspection by the Consultant and QA/QC.

2. Each material item shall be allotted a distinct and separate reference number and mentioned on the material requisition. Make sure that material is approved/examined by the Consultant and QAQC and that associated documents/test certificates are approved.

3. The Site Engineer shall be responsible for the off-loading and handling of the materials on-site and shall ensure that materials delivered to the site are properly protected against mechanical damage.

8. Resources

A. Tools and Equipment
The following type of equipment and tools shall be utilized for the installation:
a. Wire cutters
b. Hacksaw
c. Measuring tape
d. Drill machine
e. Wooden hammer
f. Flat file
g. Screwdrivers
h. Open and box spanners
i. Base Cutter
j. Drill with Bits
k. Spanners
l. Torque Wrench
m. Set Square
n. Socket wrench and sockets
o. Cranes
p. Forklift

Note:

• All testing equipment and measuring tools to be used shall have a valid calibration certificate prior to usage.
• All lifting equipment and machines shall be 3rd party certified with valid certificates.

B. Materials

a. The material shall be used after being approved by Approved Material Submittals.
All materials to be used shall conform to the project specification.

C. Site Preparation and Planning

C.1 Preparation

The main Contractor shall ensure that all gate passes, permits, tools, materials for safety precautions, manpower, and equipment are available before the commencement of work.
The Site Team shall make sure that access roads are always clear from any obstruction and site is always accessible.

C.2 Site clearance

Before commencing the work, the area shall be cleared of all debris, materials, or other obstructions.

C.3 Traffic Management

The Site Team with the assistance of the Safety Officers shall coordinate logistics and materials movement through the site following the direction and road signs displayed on site. The required diversion routes shall be marked on drawings including the required traffic signs.

The Work Permits and Operator Certificates shall be compiled and filed for reference by authorized personnel. Temporary traffic signs, barriers, and flagmen will be deployed to control traffic flow in accordance with and Traffic Management of the HSE Plan. At the end of each ramp, there will be a transition area to give the driver the opportunity to watch the access roads before joining thereto.

C.4 Pre-construction Safety Meetings:

• The meeting shall be scheduled prior to the beginning of the work and before any Subcontractor starts on the project. Safety awareness meetings will be conducted every working day morning/every other day to brief the workforce on safety prevention measures.
• The equipment check for safety shall be recorded/ documented during the daily Safety Awareness Meeting. Traffic safety will be discussed to emphasize these meetings. Each worker will be instructed to follow specific safety requirements related to his trade. They will be required to follow installed safety signs, observe barricades, and use PPEs.
• Main Contractor Safety will perform hazard risk analysis by identifying all steps, and hazards identified in those steps, with a focus on the relationship between the work task, the tools, and the work environment. After identifying uncontrolled hazards; Main Contractor will take steps to eliminate or reduce them to an acceptable risk level.
• General Contractual Safety, Health, and Environmental Requirements.
  Roles of the contractor, subcontractors, authorized representatives, and all project workers.
  Accident reporting requirements.
  Specific details of the work to be performed along with the use of personal protective equipment.
  Emergency procedure.

C.5 Operating Procedures:

A site investigation has to be carried out to develop safety precautions and measures prior to the commencement of the work. After such investigation, relevant signboards will be displayed and barricades will be installed where and as necessary, such as but not limited to the following:

• Relevant information, advanced signs, warning, and mandatory signs will be placed as required.
• Radio Communication systems would be used where normal communication is impossible. After completion of the work, safety cones and barricades have to be removed accordingly.

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9. Procedure

A. Pre-Installation

a. All relevant documentation approved shop drawings and material applicable to a particular section of works will be checked by Site Engineer prior to commencement of work.

b. Ensure that the material received is in compliance with the project specifications and is approved.

c. Ensure that all required materials and accessories are delivered, inspected, and approved by the Consultant and are readily available at the site to carry out the work and coordinated with related Civil contractors.

d. Prior to the commencement of work, areas, and access will be inspected to confirm that the site is ready to commence the work.

e. All relevant documentation (including Method Statement for Installation of Cable Trays, Ladders, and Trunking System and RA are approved, obtain necessary work permits, fill up STARRT cards after completion of daily toolbox talk), approved shop drawings, and material applicable to a particular section of works will be checked by Site Engineer prior to commencement of work.

f. The Site Engineer/Site Supervisor will give necessary instructions to tradesmen (Electrical) and provide necessary approved construction/shop drawings.

g. The Site Engineer/Site Foreman will check that proper tools and equipment are available to carry out the work and are in compliance with contract specifications.

h. The Site Engineer will explain to his team about HSE precautions to be observed.

i. The Site Engineer/Foreman ensures the cleanliness of the area.

B. Installation

The cables shall be routed on the cable ladder and tray as far as is practicable. The cable containment system includes ducts, trays, supports, a trunking system, a ladder, road crossing ducts, and associated fittings/supports. A particular installation of Cable trays/ladders and cable trunking systems is discussed below.

B.1 Installation of Cable Trays/ Ladders

1. Cable Ladders, cable trays, and their supports should be strong enough to meet the load requirements of the cable management system including cables and any future cable additions or any other additional loads applied to the system.

2. Fish plates or approved jointing materials as applicable (as per approved drawings and project specifications) to be used at tray joints for tray sizes 400 mm and above.

3. Types and sizes of cable tray and ladder supports shall be as per approved shop drawings and project specifications.

4. Cable Ladder is suitable for a power cable for HV/MV/LV large cables, made up of rungs with a rigid profile. However, Cable Tray is made of a bent sheet, with perforation on the base or side; suitable for the power cable and instrument/data cables.

5. When considering the installation of the cable support system it is imperative to avoid the cutting or drilling of the structural building members without the approval of the team leader.

6. Cables installed on ladder racking shall be spaced by one clear cable diameter of the largest cable.

7. Any installed cable ladder, or cable tray can be considered structurally as a loaded beam when installed horizontally. However, any vertically oriented component, whether cable ladder, tray, or support acts structurally as a column. While installation the structural consideration of beams and columns must be considered in terms of load management of cables.

8. All beams deflect when a load is imposed. The magnitude of the deflection depends upon the load of the beam, load type, span, size of the beam, the material of the beam, and how the beam is fixed and supported. Particular attention is given while an installation by considering the above.

9. Where cable ladder and cable tray support systems are fixed to primary supports e.g. structural steelwork or elements of the building, it is important to ensure that the primary supports are strong enough to carry the imposed loads.

10. The fixings used to connect the cable ladder/tray support systems to the primary supports also need to be checked to ensure that they are strong enough.

11. When several levels of cable ladder or cable tray are mounted on the same threaded rod in a multiple-level installation, preferably shall not be the same support for tray and ladder and it shall be as per approved drawings and project specification. It is important to ensure that the total load on any pair of rods does not exceed the safe working load of the rods or their attachment points.

12. Cantilever arms horizontal runs of cable ladder or cable tray to be mounted to vertical steel, concrete, or masonry surfaces, or to channel support systems.

13. Threaded rod suspension brackets are useful when space is limited.

14. Wall support brackets are an effective way of fixing any width of a cable ladder or cable tray, running either vertically or horizontally, to a vertical support.

15. Overhead hangers enable the tray to support to be supported from a single-threaded rod giving easy access for laying cables from one side of the tray only.

16. Hold-down brackets and clips are used for securing the cable ladder and cable tray to horizontal supports. If allowance for thermal expansion is required then the brackets and clips are generally not fixed to the cable ladder or cable tray.

17. Cable ladders or cable trays should not be laid down directly onto the roof or floor of an installation. The cable ladder and cable trays should be mounted far enough off the floor or roof to allow the cables to exit through the bottom of the cable ladder or cable tray. If a channel support system is used for this purpose, mount the channel directly to the floor or roof and attached the cable ladder or cable tray to the channel using the fixings recommended by the manufacturer.

18. The Safe Working Load (SWL) specifies load test methods for determining the SWL which can be supported by the cable ladder and cable tray. There are different types of load tests depending on the span size, possibly with end reduced span size, and positions of joints.
This is particularly important for installing straight cable ladders and cable tray lengths.

19. After the supports are in place, the installation of a cable ladder or cable tray can begin at any convenient location. It is not necessary to begin at one end of the run in all cases. It is ideal if circumstances permit the layout of the system so that joints fall in the desired positions as this will visually aid installation ad also maximize the system rigidity.

20. To begin the installation, place a straight length across two supports so that the ends of the length are not directly on the support. If the support span is equal to or greater than the length of the straight lengths then bolt two lengths together for this step.

21. Place the next straight length across the next support and attach it to the previous length with a pair of coupler plates and relevant fixings with the bolt heads on the inside of the cable ladder or cable tray unless otherwise specified by the manufacturer.

22. Manufacturers’ published data should be consulted in order to ascertain the maximum span that a product can be used with and any special provisions required for long spans. Special provisions are required especially if used externally where there may be dynamic loadings.

23. Site modifications may be required sometimes during installation. Care must be taken to ensure that all modifications on-site to the cable ladder/tray are performed by competent personnel only.

24. Cable ladders or cable trays that have been hot-dip galvanized after manufacture will need to be repaired after cutting, drilling, and de-burring. Repairing a galvanized finish must be done usually a zinc-rich paint. Other protective coatings that are cut or damaged must be repaired with compatible coatings.

25. The installation of vertical runs of trays along the line of vertical expansion joints in the structure of the facility shall not be allowed.

26. Trays shall not be smaller than the minimum size stated on the Drawings or specified later and shall be so sized; if not specified, then calculate the size of the tray and submit it to the Consultant for approval. The minimum acceptable size for a cable tray shall be 50 mm.

27. Use expansion connectors where required.

28. Where specified, install warning signs at 1500 mm centers along with cable ladder/ tray.

Erection

1. Cable trays arranged one above the other shall have spacing in relation to their width not exceeding a ratio of 1:2 with a minimum distance of 150 mm. Install fixings and supports as
(a) at 2-meter centers or as specified in project documentation
(b) 150 mm from bends, tees, intersections, and risers
(c) as close as practicable to joints
(d) each side of expansion joints.

2. Supports shall be selected from the types, to suit the site conditions. These may be GI Channels or brackets, wall support brackets, cantilever beams, or steel channels.

3. Avoid mid-span joints.

4. All calculations relating to tray work and tray support demonstrating acceptable mechanical stresses and sag should be considered.

5. Flexible expansion coupler can be used to provide a semi-flexible joint where a straight cable ladder or cable tray runs span separate structures between which some relative movement is possible.

6. Horizontal and Vertical adjustable couplers may be used for fabricating fittings on-site from cut lengths of the cable ladder.

7. Fittings facilitate a change of direction or width and provide intersections between straight cable ladder or cable tray runs. Flat bend, inside or outside riser, equal or unequal tee, 4-way crossover, or reducer are examples. These may be used depending upon requirements.

8. The radius of the cable ladder and cable tray fittings is usually determined by the bending radius and stiffness of the cables installed on the ladder or tray. Typically the cable manufacturer recommends a minimum bend allowance for each type of cable.

9. The radius of the cable ladder or cable tray fitting should be equal to or larger than the minimum bending radius of the largest cable installed.

10. Accessories like dividers and covers are used for supplementary functions such as cable retention etc. Dividers are used to physically separate different types or groups of cable.

11. within one cable ladder or cable tray run, dividers should be installed prior to the cable being laid and then fastened using the fixings.

12. Covers provide mechanical and environmental protection for cables being carried by cable ladder or cable tray, which can be closed or ventilated.

13. Cable trays installed on roofs shall be supported using GI brackets or concrete blocks. A removable cable tray cover shall be fitted.

14. Access shall be available at all times to remove or replace cables with a minimum of 400 mm between trays and physical obstructions, A/C ductwork, etc.

15. Fire sealant or other approved materials to be applied wherever passing through the fire-rated wall and riser.

Earthing

1. Cable trays and accessories shall be electrically and mechanically continuous throughout their length.

2. The entire cable tray system shall be bonded and 12 mm x 2.5 mm tinned copper links shall be bolted across each joint in the system by means of a bronze nut and bolts, complete with flat and spring washers.

3. All cable trays shall be provided with earth continuity along the whole route of cable trays which shall be bonded to the main earthing system of the facility. The earth continuity copper strap shall be fixed on the cable tray by means of bolts.

4. For Earthing works refer to Approved Method Statement for Earthing.

B.2 Installation of Cable Trunking system

1. Site Supervisor/foremen will carry out a site survey and mark the route of cable Trunking per the latest approved drawings.

2. Cable Trunking shall be properly aligned, and securely fixed at a maximum of 2 meters centers on straight runs. At bends, angles, and offsets fix with additional fixings at centers not exceeding 150 mm on each side of the fitting.

3. Make a trunking joint where trunking crosses the Settlement and Expansion Joints. Make connections through slotted holes allowing a 10 mm movement horizontally and vertically. Earth continuity link across joints shall be braided copper tape which is long enough to allow for the maximum movement of trunking. Fold braid ends.

4. Fire Barriers (non-combustible, non-metallic) shall be installed where specified. Also where trunking passes through walls, floors, and ceilings and at each floor level when trunking is installed in riser ducts.

5. Make connections to conduits, multiple boxes, switchgear, switchboards, motor control centers, and distribution boards with flanged units.

6. Fix Cable Retaining Straps at not exceeding 1m centers.

7. Raceway and Wireway

(a) install products in accordance with the manufacturer’s instructions.
(b) use flat-head screws, clips, and straps to fasten the raceway channel to surfaces. Mount plumb and level.
(c) use suitable insulating bushings and inserts at connections to outlets and corner fittings.
(d) provide steel channels for supporting the wire ways.
(e) close ends of wire way and unused conduit openings.
(f) earth and bond raceway and wire way
(g) provide circuit cable clamps at no greater than 500 mm intervals for raceways installed in vertical runs.

Cleaning
a) make good cutting and damages of the steel trunking systems, remove burrs and rough edges and corrosion, and treat with a rust-proofing agent, followed by an application of zinc epoxy
(b) provide a coat of paint to match the adjacent surface for the PVC system
(c) provide the paint after the application of the zinc epoxy for the steel trunking system.

10. Health, Safety, and Environment

A. HSE Risk Assessment

Please refer to the attached document in Appendix A.

B. Permit and Licensing Requirements

The required permit to work shall be obtained prior to the commencement of work. This shall be coordinated with HSE.

C. Pre-Start Safety Briefing Arrangements

C.1 Protective and Safety Equipment

All workers involved shall be equipped with adequate PPE as stated below:
Safety Helmet with Company Logo
Safety Boots
High Visibility Vest
Safety Goggles
Hand Gloves
Coveralls
High voltage gloves (Job Specific)

C.2 Information to Personnel

Safety Induction
Job training
Superintendents Notices/Memos
Toolbox talks
STARRT Card

C.3 Special Safety Requirements:

All necessary personal/protective equipment (PPE) as well as harness be provided.
Rigging Team, wearing distinctive vests, shall be assigned to help operators manoeuver their equipment.

The equipment operators shall possess the required licenses and certificates.

Generated dust shall be controlled by periodic water spraying.

The required permit to work shall be obtained prior to the commencement of work.
The project safety officer is responsible along with the project zone site engineer for ensuring that all operations are carried out with due regard to the safety of all project personnel & property.

Working at height to be monitored with due care.

In case of working at night, please refer to Method Statement for Night Works

C.4 Emergency Procedures
(Emergency Site Contact Numbers Here)

11. Quality Assurance and Quality Control

A. Quality Assurance Requirements
The main Contractor shall provide the required documents for the Consultant’s approval prior to initiating the execution of this activity as per project specification requirements.
The Quality Control requirement shall include related to ITPs and other related documents as applicable.

Refer to Inspection Test Plan (See Attachment B)
Applicable codes and standards are referenced for materials and installation in MST.

B. Quality Assurance Process
The main Contractor shall notify the Engineer 24 hours in advance prior to the start of activity and Comments from the Site Instruction will be complied with to the satisfaction of the consultant.

The main Contractor shall consult the public utility authorities not less than one month before it is proposed to commence work to ascertain whether any underground installations will be affected by the proposed work, in which event the Main Contractor shall make all necessary arrangements with the public utility authorities to safeguard the installation.

C. Follow-up and Evaluation
Follow-up on quality performance shall be carried out through in-house monitoring systems such as progress reporting to the planning department, and daily, weekly, and monthly reports generated by the planning department to closely monitor site performance.

All of the above shall be conducted in close coordination with the quality department to monitor any deviations from the Quality Management System requirement and induce corrective actions whenever required to eliminate non-conformance or quality deviations.

D. Records
Checklists (CKL)
Inspection Request (INR)
Other Project related reports.

12. Attachments

A. Appendices
Appendix A: HSE Risk Assessment for Installation of Cable Trays, ladders, and Trunking
Appendix B: Inspection and Test Plan for Installation of Cable Trays, ladders, and Trunking
Appendix C: Checklist for Installation of Cable Trays, ladders, and Trunking
Appendix D: ITR-Earth Resistance and Continuity Test Report
Appendix E: Permanent Material Delivered Approval form

tag: Method Statement for Installation of Cable Trays, Ladders, and Trunking System

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